{"id":12805,"date":"2026-09-16T08:56:02","date_gmt":"2026-09-16T12:56:02","guid":{"rendered":"https:\/\/robodk.com\/blog\/?p=12805"},"modified":"2026-09-16T09:08:22","modified_gmt":"2026-09-16T13:08:22","slug":"access-cut-aerospace-inspection-documentation-using-robodk","status":"publish","type":"post","link":"https:\/\/robodk.com\/blog\/access-cut-aerospace-inspection-documentation-using-robodk\/","title":{"rendered":"How Access e.V. Cut Aerospace Inspection Documentation Time by a Third Using RoboDK"},"content":{"rendered":"\n

Aerospace components must meet exacting industry standards. Investment-cast parts, including turbine blades and structural components, must be inspected for even microscopic imperfections before they can be approved for use.<\/p>\n\n\n\n

To help automate this demanding and time-consuming manual task, Access e.V.<\/a>, a German research institute specializing in materials and process development, created a robotic system for documenting fluorescent penetrant inspections (FPI).<\/p>\n\n\n\n

Developed within the publicly funded GATE and FAST projects, the system combines a Rainbow Robotics RB5-850<\/a> collaborative robot, automated image capture, AI-assisted image analysis and RoboDK<\/a>.<\/p>\n\n\n\n

Access e.V. presented the system as a technical demonstrator at the ILA Berlin Air Show 2026. The cell shows how robotics, offline programming and simulation software can improve the speed, flexibility and ergonomics of aerospace quality inspection.<\/p>\n\n\n\n

The challenge: Complex components in a confined cell<\/h2>\n\n\n\n

During fluorescent penetrant inspection, a penetrant is applied to the component. A substance called a developer then draws the penetrant out of any defects. The component is examined under UV light from multiple angles so that potential imperfections can be identified and documented.<\/p>\n\n\n\n

Automating this documentation stage is challenging. Investment-cast parts often have complex, organic and asymmetrical geometries. Every new component requires a different sequence of movements to ensure that all relevant surfaces are presented clearly to the inspection camera.<\/p>\n\n\n\n

Access e.V.\u2019s solution places the RB5-850 cobot inside a compact, darkened inspection cell. The robot grips the component and moves it through a controlled sequence of orientations in front of a stationary camera. High-resolution UV images are captured from every required angle.<\/p>\n\n\n\n

The confined workspace creates a persistent collision risk. The robot arm, gripped component, camera and cell infrastructure must all be considered when trajectories are calculated. Programming and testing every movement on the physical robot would take several hours. It could also place the equipment and valuable aerospace components at risk.<\/p>\n\n\n\n

\u201cManually programming the robot would take several hours, as the operator would have to adjust coordinates, check the camera focus, readjust the positioning, and so on. With RoboDK, we can check and adjust the positioning virtually and in real time before applying it to the actual robot\u201d – David Geibel, Project Engineer at Access e.V.<\/p>\n\n\n\n

<\/em>
<\/em>RoboDK software provided a full simulation and offline programming environment for the team at Access e.V. to work with. Credit: Access e.V. <\/em><\/p>\n\n\n\n

Remote programming and virtual validation with RoboDK<\/h2>\n\n\n\n

Access e.V. uses RoboDK as the central offline programming and simulation platform for the robotic cell.<\/p>\n\n\n\n

The team imports the CAD data for each component and creates a virtual model of the robot, component and inspection environment. RoboDK then automatically calculates the handling trajectories required to present the component to the camera from the necessary viewpoints.<\/p>\n\n\n\n

\u201cThe biggest advantage for us is the ability to program the robot remotely,\u201d says Geibel. \u201cWe don\u2019t need to physically access the inside of the machine every time we want to change or adjust a robot position.\u201d<\/p>\n\n\n\n

This approach eliminates the need to program every movement manually inside the inspection cell. Before a program is transferred to the RB5-850, the complete image-capture cycle can be simulated and checked in RoboDK.<\/p>\n\n\n\n

RoboDK also calculates the movements so that collisions between the robot arm, casting and surrounding infrastructure are ruled out from the beginning.<\/p>\n\n\n\n

\u201cThanks to RoboDK, we were able to fully validate our handling trajectories and collision avoidance virtually,\u201d says Geibel. \u201cThis allows us to ensure the system runs smoothly before the robot makes a single real-world movement.\u201d<\/p>\n\n\n\n


RoboDK enables high-fidelity simulations of complex cells. Credit: Access e.V. <\/em><\/p>\n\n\n\n

Virtual testing also reduces the consequences of programming errors.<\/p>\n\n\n\n

\u201cLast but not least, if we have a collision in RoboDK, we can simply reset the program without risking damage to the actual parts or the robot,\u201d Geibel explains.<\/p>\n\n\n\n

Cutting documentation time by around one third<\/h2>\n\n\n\n

Automated image capture delivers a considerable time saving. Instead of relying on an inspector to reposition and examine the component manually, the robot moves through a repeatable sequence of camera positions.<\/p>\n\n\n\n

\u201cThere is definitely a considerable time-saving aspect to having automated image capture,\u201d explains Geibel. \u201cBy having the robot cycle through the different positions in a controlled manner, we can save roughly one third of the time, depending on the complexity of the part and the number of images required.\u201d<\/p>\n\n\n\n

Offline programming also allows Access e.V. to prepare upcoming components while the FPI cell continues capturing images.<\/p>\n\n\n\n

\u201cA second major benefit is the time savings, as we can run the machine while programming the next parts in parallel,\u201d Geibel says.<\/p>\n\n\n\n

Programs for new components can therefore be generated, simulated and validated on a PC. They do not need to be developed through trial and error on the physical system. Inspection work can continue without interruption, eliminating the downtime traditionally associated with programming a new application directly on the robot.<\/p>\n\n\n\n

By automatically generating trajectories from component data, Access e.V. can integrate new parts in record time while maintaining 100% collision safety. Virtual validation protects the robot, camera equipment and valuable cast components from costly crashes inside the confined cell.<\/p>\n\n\n\n