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Manual measurements are also slow and labor-intensive. Each dent must be evaluated individually, using multiple tools and repeated steps, which significantly extends inspection times—especially when access is difficult or when multiple damage sites must be assessed across large fuselage or wing surfaces.
Beyond the measurement itself, documentation remains one of the most persistent bottlenecks. Data is frequently captured through handwritten notes, unscaled photos, or simplified sketches that provide limited spatial context. Complex damage, such as hail strike clusters, blended dents, or deformations near structural features, further increases the risk of inaccurate assessments.
In short, when data quality is low, structure engineers often default to conservative decisions, resulting in extended aircraft downtime and, consequently, higher aircraft on ground (AOG) costs.
EVO Series—Redefining Aircraft Surface Integrity Assessment
The HandySCAN 3D EVO Series is already making a strong impression across the industry with its embedded touchscreen display, built-in photo camera, laser pointer, and augmented-reality features. These technologies directly address the operational challenges faced by airlines and MROs by delivering highly accurate and repeatable measurements. With a simplified user interface, the EVO Series guides aircraft technicians through every step of data acquisition and photo capture, while providing structures engineers with the clear, consistent information they need for confident report generation.
Augmented Reality Analysis
The EVO Series integrates augmented reality (AR) to give technicians immediate, in-context visibility of their analysis—enhancing inspection quality and accelerating data validation. With the Analysis On-site feature (AR combined with the live camera feed), dent colormaps and contour outlines are overlaid directly onto the aircraft’s damaged surface, ensuring a more reliable assessment before moving on to reporting.
Reporting
All photos and AR-enhanced visuals captured with the EVO Series can be automatically integrated into the predefined report templates, eliminating manual data transfer and saving significant post-processing time. By producing structured, image-rich PDF reports without manual input, the EVO Series enhances inspection compliance and ensures consistent, error-free documentation.
Simplifying the Path from Damage Characterization to Reporting
For MROs and airlines, the EVO Series brings clarity, consistency, and speed to dent assessment—three elements that traditional methods often struggle to deliver. By removing human interpretation, the 3D scanner ensures repeatable measurements, reducing the confusion and miscommunication that typically arise during manual inspections. The advanced augmented reality tools further simplify damage characterization and documentation by allowing dents to be visualized and analyzed directly on the aircraft surface.
Technicians also benefit from a more fluid and intuitive process. Dents can be selected with a simple laser pointer, and all essential information is displayed on the embedded screen, eliminating constant back-and-forth to a computer. This streamlined process accelerates inspection, supports more accurate reporting, and reinforces traceability—replacing pen marks and visual estimation with reliable, human-independent results.
Because the interface is pre-configured and easy to learn, technicians with limited experience or training can achieve consistent results. This helps MROs and airlines maintain high inspection quality even when staffing levels or expertise vary.
In short, the EVO Series is purpose-built for aircraft surface assessment. It delivers more accurate and reliable aircraft surface assessments, minimizes human variability, and ultimately supports faster, more informed maintenance decisions for both MROs and airlines.
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Published 02/23/2026