Airframe Manufacturing and Maintenance

Aircraft Structural Monitoring Solutions

Structural monitoring is used throughout manufacturing and maintenance to track strain, assess material performance, and verify electrical continuity. Fiber optic sensors and bond meters help identify potential failures before they lead to safety or reliability issues. These systems are part of routine workflows across airframe production lines, flight lines, and service operations in both commercial and military settings.
 

Real-Time Structural Health Monitoring with FBG Sensors

Fiber Bragg Grating (FBG) sensors are used to monitor strain, vibration, and temperature in real time across structural components. They play a role in structural health programs that support both production testing and ongoing maintenance.

Advanced Energy’s WaveCapture Interrogator, Analyzer Series, and Analyzer-IRS are designed for fiber optic sensing across multiple channels and wavelengths. These systems operate with sub-millisecond response times and high wavelength accuracy. They rely on solid-state electronics, require no moving parts, and are calibrated for long-term stability.  

Electrical Bond Integrity Testing

Bond testing is essential throughout the airframe lifecycle. During manufacturing, handheld bond meters such as the TEGAM 710A are used to verify mechanical and electrical joints across structural assemblies, electrical panels, and ground paths. The TEGAM 730A supports inspection and documentation through its wireless datalogging capability.

For maintenance providers working on fueled aircraft, intrinsically safe instruments are required. The TEGAM 720A is designed for use in environments with flammable vapors, gases, and mists. It is suited for continuous service during flight line and MRO operations. All three models are known for precision, usability, and long battery life.  

Thermal Monitoring Solutions

Thermal processes influence structural durability, avionics performance, and the behavior of composite materials across aerospace platforms. Temperature must be monitored during manufacturing, validated during integration, and checked during in-service inspections. Instruments such as thermal imagers, pyrometers, thermocouple thermometers, and calibrators are used throughout these stages to help control and verify critical thermal conditions.
 

Thermal Imaging for Critical Component Monitoring

Thermal imaging allows technicians to visually assess heat distribution across systems without physical contact. Applications include composite structures, engine systems, and electronic enclosures. This method is used during assembly, inspection, and diagnostic work.

The Mikron MCL640 is built for demanding aerospace settings. It measures temperatures from –40 to 1600°C and provides ±2°C accuracy. With a rugged design and maintenance-free electronics, it supports long-term thermal monitoring in both production and field environments. A wide range of accessories extends its flexibility for different installation or inspection needs.  

Non-Contact Temperature Measurement

Non-contact pyrometers are used to measure surface temperatures during both manufacturing and maintenance. These readings are often required in high-heat or difficult-to-access areas where contact-based sensors would not be suitable.

Advanced Energy’s Impac pyrometers are used throughout the aerospace supply chain. They are known for accurate readings, fast response times, and compatibility with automated test setups. Common applications include composite curing and engine inspections.  

Precision Temperature Monitoring and Calibration

High-precision thermocouple measurement is a cornerstone of aerospace thermal testing and calibration. These processes support work across bonding, curing, component assembly, and structural repair. Reliable data is essential to avoid quality escapes and meet program specifications.

Advanced Energy’s TEGAM thermocouple thermometers and temperature calibrators feature digital functionality and intrinsic safety. They are used for calibration routines, test system verification, and in-process monitoring. These instruments are deployed in production lines, flight line operations, and field maintenance programs.