Overview

In aerospace and defense manufacturing, even the smallest assembly defects can have outsized consequences. A misaligned rivet or misplaced gasket not only risks mission failure but also leads to rework, delays, and regulatory penalties.

NorrStudio, developed by the Swedish AI pioneer NorrSpect, brings intelligent visual inspection to the most demanding environments. With deep learning models trained on high-compliance assembly standards, NorrStudio is designed to support fabrication precision, QA traceability, and process integrity across both airframe and subsystem assembly operations.

About NorrSpect

Headquartered in Umeå, Sweden, NorrSpect specializes in AI-powered industrial inspection systems. With a history of delivering high-precision solutions to global manufacturers such as Volvo Cars, NorrSpect extends its AI innovation to aerospace and defense production—where reliability and repeatability are non-negotiable.

Industry Challenge: Human Limitations in Complex Assembly QA

Despite robust assembly protocols, manual inspections remain vulnerable to human fatigue, documentation lapses, and inconsistency—especially when working with concealed fasteners, layered wiring, or transparent sealants.

Key fabrication defects that often go undetected or underreported include:

• Tilted or missing rivets in multi-panel assemblies

• Improper torque seals on fasteners or bolts

• Sealant voids or gaps in pressure- or fluid-critical joints

• Incorrect wiring routing within equipment bays

• Gasket misplacement in doors, panels, or seals

• Glue overspray or leakage during final fitment

These can lead to:

• Assembly rework or rejection

• Functional failure during testing

• Non-compliance in regulatory audits

• Increased lifecycle maintenance cost

• Safety and reliability concerns

Solution: AI-Driven Assembly Line Inspection with NorrStudio

NorrStudio integrates seamlessly into aerospace production lines or final assembly stations to identify subtle defects that human inspectors may overlook. Using a mix of 3D vision, structured light imaging, and deep learning algorithms, it brings aerospace-grade accuracy to every inspected unit.

Core Detection Capabilities:

• Rivet angle, gap, and presence validation using positional geometry modeling

• Torque seal verification by detecting color-coded indicator smear, alignment, and coverage

• Sealant bead continuity check with AI trained on gap detection and void recognition

• Wiring bundle conformity to expected routes, clip positions, and tension indicators

• Gasket placement inspection with edge tracing and surface pressure variance mapping

• Overspray/glue leak identification using contrast, shape, and dispersion analysis

Deployment Snapshot

• Facility Type: Defense systems integrator – fuselage and subsystem assembly

• Deployment Point: Final assembly & inspection zone

• Cycle Time: ~7 seconds per scanned component section

• Reporting: Pass/fail decision, annotated defect image, severity level, batch traceability

• Data Integration: ERP, PLM, and QA non-conformance workflows

Use Case: UAV Airframe Assembly Facility

Problem:

A UAV (Unmanned Aerial Vehicle) manufacturer faced repeat quality issues during system integration, including:

• Sealant voids near avionics cooling ducts

• Incorrect routing of shielded cable bundles

• Misplaced gaskets leading to cabin pressurization rejections

• Torque marks missing or mismatched on key structural fasteners

These were often caught late—during test runs or audits—leading to costly rework and schedule slippage.

Solution:

NorrStudio was installed along the assembly line and configured to scan for known defect classes in rivet alignment, sealant spread, and routing compliance. It was integrated into existing QC workflows with minimal hardware modification.

Outcome Over 60 Days:

• Detected defects in 4.7% of assemblies that passed visual inspection

• Enabled real-time rework before line progression

• Improved QA report generation with automated visual documentation

• Reduced customer-detected NCRs by 72% in post-delivery audits

• Provided training feedback for technicians based on defect heatmaps

Impact Metrics

Why Aerospace Manufacturers Choose NorrStudio

• Detects complex, low-contrast assembly flaws not visible to the human eye

• Enhances first-time-right assembly rates

• Supports regulatory documentation with time-stamped, annotated visuals

• Adapts to custom assembly geometries and dynamic lighting

• Trains itself over time to detect emerging or rare defects

• Seamlessly integrates with existing MES and QA systems