Fraunhofer Develops GiantEye High Energy Computed Tomography System for Industrial Inspection of Large and Complex Components

© Fraunhofer IIS
Gantry design based on medical CT scanners: The radiation source and detector rotate vertically around the test object in a gantry configuration. This enables the examination of large objects in their natural horizontal orientation without having to set them up on one side first.

(IN BRIEF) Fraunhofer is developing the GiantEye high-energy computed tomography system to enable nondestructive testing of large and complex objects with unprecedented detail. The system uses a gantry-based design that allows large components such as vehicles, aircraft parts and high-voltage batteries to be scanned in their natural horizontal position, reducing mechanical stress and simplifying handling. Equipped with a nine-megaelectron-volt linear accelerator and high-precision detectors, GiantEye can achieve measurement resolutions down to 100 micrometers while imaging dense and thick materials. The system’s industrial scanning architecture allows routine CT inspections without complex preparation and is expected to be available to industrial partners by early 2027. In addition to hardware development, researchers are creating advanced data-processing tools to manage the large volumes of imaging data, with the aim of transforming quality assurance and product development for large technical systems.

(PRESS RELEASE) MUNICH, 3-Mar-2026 — /EuropaWire/ — Fraunhofer is developing a new high-energy computed tomography system designed to enable nondestructive testing and digital inspection of very large and complex components with unprecedented precision. The system, known as GiantEye, is being created by the Fraunhofer Institute for Integrated Circuits IIS at its Development Center X-Ray Technology in Fürth and is intended to expand the possibilities of industrial CT scanning beyond the limits of existing technologies.

© Fraunhofer IIS
Birds-eye view of the GiantEye high-energy computed tomography system

Nondestructive testing makes it possible to examine the internal structure of objects without dismantling or altering them. Conventional CT systems, however, are restricted by the size and weight of the objects they can accommodate. Fraunhofer IIS previously addressed this limitation with an XXL CT system introduced in 2013, which remains the only publicly accessible facility capable of scanning entire vehicles and freight containers. Despite its capabilities, that system requires complex positioning and preparation of test objects.

The new GiantEye system significantly advances this technology by introducing a gantry-based design similar to that used in medical CT scanners. In this configuration, the radiation source and detector rotate vertically around the test object while the object remains in its natural horizontal position. This approach eliminates the need to reposition large components on their sides and reduces mechanical stress that could otherwise distort measurements or damage the object. The improved setup enables reliable scanning even in highly absorbent regions, such as the battery systems of electric vehicles. The technology is expected to become available to industrial users in early 2027.

At the core of the GiantEye system is a linear accelerator that produces X-ray energies of up to nine megaelectron volts. Combined with advanced detector technology and a highly precise manipulation system, the equipment can achieve three-dimensional measurement resolutions as fine as 100 micrometers. This configuration allows accurate imaging of dense materials and thick components commonly found in complete vehicles, aircraft structures and high-voltage battery assemblies. The precision positioning system helps ensure consistent image quality with minimal artifacts.

A defining characteristic of GiantEye is its industrial scanning architecture, which integrates high precision with efficient operation. This design makes routine CT inspection of large components feasible without extensive preparation or complex handling procedures. The horizontal gantry arrangement shortens scanning times, improves image quality and reduces the risk of damage to sensitive components, particularly in safety-critical applications such as battery system evaluation.

The system is expected to support a wide range of industrial and research applications. Potential uses include analyzing crash-test vehicles, inspecting additively manufactured components, and performing material diagnostics on large engine parts. Comparable large-scale CT developments have already demonstrated their value in research settings, such as the Gulliver CT system at the Technical University of Kaiserslautern, which has been used since 2024 to examine loaded concrete beams in three dimensions. GiantEye builds on this progress and extends the concept toward practical industrial deployment.

The technology also offers potential benefits for public safety by enabling detailed inspection of sealed transport units without requiring them to be opened. This capability could improve efficiency and accuracy in security screening while reducing handling effort.

Fraunhofer researchers aim to make GiantEye available worldwide for industrial applications, supported by a modular system architecture that allows customized solutions for different testing requirements. The system is expected to be relevant across multiple industries, including automotive manufacturing, aerospace engineering and energy technology.

In parallel with hardware development, the research team is advancing data processing and automation capabilities. High-energy CT scans generate extremely large datasets that require new algorithms for fast reconstruction and analysis of three-dimensional images. The project is therefore focused not only on building advanced measurement equipment but also on creating a comprehensive data-processing environment that supports efficient use of scan results. Once routine operation begins, the GiantEye system is expected to significantly improve quality assurance and product development for large-scale technical systems.

Media Contact:

Thomas Kestler
Division Communications
Fraunhofer Institute for Integrated Circuits IIS
Flugplatzstr. 75
90768 Fürth, Germany
Phone +49 911 58061-7611
Fax +49 911 58061-7599
thomas.kestler@iis.fraunhofer.de
www.iis.fraunhofer.de

SOURCE: Fraunhofer-Gesellschaft