In the automotive, aerospace, and rapidly growing E-Mobility (EV) sectors, as the parts to be inspected become larger and more complex, there is an increasing demand in R&D and quality assurance environments for both high resolution to capture microscopic defects and high energy to penetrate thick, high-density materials.

Comet Yxlon’s FF85 CT is a high-end industrial X-ray CT inspection system developed to meet these stringent requirements. Its greatest feature, the Dual Tube & Dual Detector configuration, provides unparalleled precision and versatility in a single system, handling everything from minute electronic components to extra-large parts weighing up to 1,000 kg.

In this article, aimed at customers seriously considering implementation, we will explain the outstanding hardware performance of the FF85 CT and the advanced software solutions that dramatically enhance scanning efficiency.

Outstanding Hardware Design Characterizing the FF85 CT

The FF85 CT adopts a robust and flexible system architecture worthy of a high-end machine.

Dual Tube & Dual Detector Configuration for a Wide Range of Inspection Tasks

The FF85 CT can be configured as a unique system equipped with two X-ray tubes and two detectors, which can be selected according to the inspection purpose.

• X-ray Tube Combination: Can be equipped with a mini-focus X-ray tube up to 600 kV, which is powerful for penetrating high-density and large parts, and a micro-focus X-ray tube up to 300 kV (or the proprietary 450 kV meso-focus X-ray tube, etc.) that clearly captures the fine structure of small parts. These can be seamlessly switched within the same CT sequence, covering a broad scanning range from macro to micro.
• Detector Combination: By utilizing a large-area flat panel detector (DDA) compatible with high energy, which achieves a wide field of view and high-speed scanning, together with the proprietary line detector array (LDA) described below, you can smoothly switch between 2D fluoroscopy, 3D cone-beam, and fan-beam CT, building the optimal inspection process tailored to the part.

Proprietary Line Detector CTScan 3 for Extreme Scatter Reduction

Scatter radiation is the biggest obstacle in CT scanning of thick metal parts and large components. The line detector CTScan 3, specially developed by Comet Yxlon, supports tube voltages up to 600 kV and drastically reduces physical scatter radiation.
The combination of a 254 μm pixel pitch, low-noise electronics, and a high-efficiency scintillator achieves an unprecedented signal-to-noise ratio and dynamic range. It is the definitive solution for visualizing the internal structure of large castings and high-density parts with clear, noise-free images.

Granite Base Supporting Large Parts up to 1,000 kg and Ensuring Precision

The large-scale configuration of the FF85 CT allows loading of extraordinarily large parts (such as entire EV battery packs) up to 1,800 mm in diameter, 3,000 mm in height, and 1,000 kg in weight.
To continue scanning such heavy objects with high precision, the base of the manipulator utilizes an extremely robust granite base. It minimizes thermal expansion due to temperature changes and prevents warping or distortion even with long-term use, permanently maintaining precision manipulation of up to 7 axes and high dimensional measurement accuracy.

Software Suite That Dramatically Enhances Inspection Efficiency and Image Quality

To maximize its top-class hardware performance, the FF85 CT is equipped with a powerful software suite built on three pillars: Clarity, Efficiency, and Insights.

Advanced Image Quality Optimization Tools via Software

It clears up image quality using advanced algorithms to address physical phenomena that hardware alone cannot compensate for.

• ScatterFix 2.0: Reduces scatter radiation during cone-beam CT scanning via software processing, supporting the extraction of optimal surface geometries.
• Beam Hardening Correction (BHC): Corrects unwanted gray value gradients (cupping artifacts) appearing in homogeneous materials, enabling highly reliable porosity analysis.
• Metal Artifact Reduction (MAR): Effectively reduces intense metal artifacts that obscure low-density materials, which occur in composite parts where resin and metal are mixed.

Vista Package and Advanced Scan Trajectories for Maximum Productivity

The optional Vista series packages are available, achieving both reduced scan times and higher image quality.

• HeliExtend / ScanExtend: Enables flexible partial or full scanning of large parts through helical scanning, which avoids cone-beam artifacts prone to occur when inspecting vertically long parts, and horizontal/vertical field of view (FOV) extension features.
• ZoomScan (Included in Vista X): During the rotation of the CT scan, linked with the automatic collision prevention function (SmartGuard), the X-ray source is dynamically kept as close to the complex contour of the part as possible. This achieves an overwhelming resolution improvement up to 10 times compared to conventional standard scans (QualityScan). It allows extremely high-definition observation even in specific areas of large parts.
• FlexCenter: There is no need to laboriously precisely center the object on the rotation axis (the center of the turntable) every single time. By simply setting a virtual rotation axis on the screen, the turntable itself moves and rotates so that the region of interest of the part is centered. This saves the trouble of repositioning heavy parts, enabling efficient and accurate scanning.

AI-Based Advanced Analysis Software Dragonfly 3D World

An AI-driven analysis tool designed to extract valuable insights about the product from the acquired high-quality volume data.
Using deep learning, it rapidly and intuitively executes the automatic segmentation of millions of individual pores and particles, visualization of wall thickness distribution using color coding, and comparative analysis of deviations and warpage between design data (STL) and the actual parts.

Geminy Interface for Intuitive Operation and Automation

No matter how highly functional a CT system is, complex operation becomes a bottleneck on the shop floor. The FF85 CT features Geminy, a system user interface that enables intuitive touch-screen operation.

With graphical icons and extensive wizards (such as the automatic collision prevention feature by SmartGuard), complex scan setups can be performed safely and easily regardless of the operator’s skill level. Furthermore, the Batch Manager feature flexibly supports inline integration and automation (Efficiency) of the inspection process, such as loading multiple parts and executing batch scans automatically.

FF85 CT Product Introduction Video

Key Application Areas for the FF85 CT

Thanks to its overwhelming versatility, the FF85 CT is active in non-destructive testing, dimensional measurement, failure analysis, and reverse engineering across a wide variety of industries and objects, including:

• Automotive / E-Mobility: Inspection of entire EV battery cells, modules, and systems; large aluminum die castings (e.g., gigacastings).
• Aerospace / Metalworking: Turbine blades, steel/superalloy components, complex additive manufacturing (3D printed) parts.
• Electronics / Composite Materials: Complex mechatronics modules, fiber-reinforced plastics (CFRP/GFRP), large resin injection molded parts.
• Science / Research: Geological, paleontological, and biological sample analysis; digitization of cultural heritage.

Summary

Comet Yxlon’s FF85 CT goes beyond a mere CT for large parts; it is a high-end solution with ultimate versatility that completes inspections of any scale and material with extremely high precision via its dual-tube and dual-detector configuration.

Pushing the boundaries of R&D and elevating the quality assurance processes on the manufacturing floor to the next generation, the FF85 CT is the solution for your advanced inspection challenges.
For more detailed product specifications, custom configurations, or to consult about a scan test using your own samples, please feel free to contact us.