Industrial CT scanning is revolutionizing the way manufacturers, engineers, and researchers inspect and analyze the internal structures of materials—without cutting them open. Whether it’s checking for defects, verifying internal dimensions, or reverse engineering parts, CT (computed tomography) offers unmatched visibility.
But here’s a common question: What materials can be scanned using industrial CT?
The answer? A wide range—but with some important nuances depending on the material’s density, thickness, and geometry. In this guide, we’ll break down the types of materials that are most suitable for industrial CT scanning, the factors that affect scan quality, and what you should consider when selecting materials for inspection.
First, a Quick Recap: What Is Industrial CT?
Industrial CT scanning services operate much like medical CT scans, but they’re specifically designed for inspecting objects instead of people. A part is placed on a rotating platform, and as it spins, a powerful X-ray source shoots rays through it. A detector captures the X-rays that pass through, and advanced software reconstructs them into a 3D model. This model reveals internal features, defects, and structures that would be otherwise hidden.
Categories of Materials Suitable for Industrial CT
Let’s explore the broad categories of materials that can be scanned, starting with the easiest and moving toward the more challenging:
1. Plastics and Polymers
Plastics are some of the best materials for CT scanning.
- Why? Plastics are low in density, meaning X-rays can pass through them easily.
- Examples: ABS, nylon, polyethylene, polypropylene, and polycarbonate.
- Applications: Checking for voids in molded parts, ensuring dimensional accuracy, inspecting assemblies with embedded components.
Bonus: You can often scan plastic parts at high resolution and with minimal exposure time, making this process fast and cost-effective.
2. Composites and Fiberglass
Composites combine two or more materials (like carbon fiber and resin) to produce lightweight, strong components. These materials are widely used in aerospace and automotive sectors.
- Why? Many composites are low-to-medium in density and have layered structures that can be inspected for delamination or voids.
- Applications: Inspection of aerospace parts, automotive panels, sports equipment.
CT scanning is ideal for catching hidden structural issues in composites without damaging them—something traditional methods struggle with.
3. Ceramics
Ceramic materials used in industrial applications, such as heat shields, spark plugs, and medical implants, are excellent candidates for CT scanning.
- Why? While denser than plastic, ceramics allow X-rays to penetrate well enough for detailed internal imaging.
- Applications: Failure analysis, structural integrity checks, porosity assessment.
With high-resolution scanning, tiny cracks, inclusions, or voids inside ceramic materials can be detected before they cause failure.
4. Light Metals (Aluminum, Magnesium, Titanium)
These metals are common in manufacturing and engineering, and CT scanning can capture their internal structures in great detail.
- Why? Their moderate density makes them scannable with standard or high-power industrial CT systems.
- Examples: Aluminum alloy engine parts, titanium implants, magnesium housings.
- Applications: Dimensional analysis, porosity detection, weld inspection, and quality control.
Note: As density increases, the scan may require more powerful X-ray sources and longer exposure times.
5. Dense Metals (Steel, Copper, Lead)
Now we’re getting into trickier territory. Dense metals can be scanned, but there are some limitations.
- Why is it challenging? Dense metals absorb more X-rays, making it harder for enough of them to reach the detector.
- What helps? High-energy X-ray systems (up to several MeV) or dual-energy CT systems.
- Applications: Weld inspection, internal corrosion analysis, crack detection.
For thin or small parts made of dense metals, CT can still produce excellent results. However, scanning thick steel components or large lead parts may not yield clear images.
6. Multi-Material Assemblies
Many modern components—especially electronics—contain a mix of materials like metals, plastics, ceramics, and adhesives.
- Why it’s complex: Materials with different densities can cause artifacts in scans, especially when denser materials overshadow lighter ones.
- Examples: Circuit boards, electronic connectors, composite assemblies.
- Applications: Short detection, solder joint inspection, internal layout verification.
With the right calibration and scanning parameters, industrial CT can successfully analyze complex, multi-material parts, even if some compromises on resolution are needed.
Factors That Affect What Can Be Scanned
While many materials are compatible with CT scanning, a few key factors determine success:
1. Density and Thickness
Higher-density materials absorb more X-rays. If the material is thick and dense (like a steel block), it may require a more powerful CT scanner or might not be scannable at high resolution.
2. Part Size
Large parts need more space and X-ray penetration. Some scanners are built specifically for large-scale items, while others are designed for small, detailed parts.
3. Contrast Between Materials
If you’re scanning an object made of similar materials (e.g., plastic-on-plastic), contrast might be low, making it hard to distinguish internal boundaries. Multi-material parts with distinct densities show clearer contrast.
4. Desired Resolution
Scanning a tiny crack in a circuit board requires much higher resolution than scanning a car part for general defects. The required detail determines the scanning setup and feasibility.
Materials That Are Not Ideal for CT
While industrial CT is incredibly versatile, there are a few situations where it may not be the best choice:
- Extremely dense materials (like tungsten or thick lead blocks): Difficult or impossible to scan with standard systems.
- Large, homogeneous parts: If there’s nothing to “see” inside (like solid, flawless slabs), the scan might not provide useful data.
- Highly reflective materials: Some metal surfaces may cause artifacts unless properly prepared.
Conclusion: CT Is a Versatile Tool—With Limits
Industrial CT is a powerful, non-destructive way to peer inside objects with stunning clarity. From plastics and composites to metals and electronics, a wide range of materials can be scanned effectively. However, the feasibility depends on size, density, resolution requirements, and the available scanner technology.
If you’re considering CT scanning for your materials or parts, the best approach is to consult with a CT service provider. They can guide you on scanability, expected results, and the optimal setup for your specific needs.
In short: If it fits and the X-rays can get through, industrial CT can probably scan it—and tell you more about what’s inside than any other inspection method.
