The future of aerospace: Breaking the quality vs. speed trade-off in manufacturing

In aerospace manufacturing, quality isn’t a checkpoint. It’s a continuous, embedded process that determines whether innovation takes flight or falls short.

From high-precision engine components to complex assemblies that must endure extremes of speed, pressure, and temperature, the industry’s tolerance for variation is virtually zero. And yet, many manufacturers still treat quality as a retrospective task. This creates bottlenecks, rework, and missed opportunities. All this, in a sector where delivery backlogs are already mounting and sustainability pressures are intensifying.

The peak of this pressure exists at the junction of ‘complexity’ and ‘urgency’. Across all industries, there is the relentless pressure to increase production speed, meet demand surges, and reduce costs. In aerospace, this is particularly acute.

OEMs and suppliers are being asked to do more, faster:

• Ramp up production to meet demand

• Integrate new propulsion systems (electric, hybrid, hydrogen)

• Adopt sustainable materials

• Maintain unwavering safety and compliance

The need to maintain high-quality standards is more critical than ever. This is especially true in industries like aerospace, automotive, and medical manufacturing, where precision is non-negotiable. But this is happening at a time of workforce shortages and digital fragmentation.

So, the traditional solution has always been that manufacturers had to prioritise quality or speed. What if they no longer had to?

With the rise of digital manufacturing, metrology is no longer just a checkpoint at the end of production. It’s not a room at the end of the process slowing things down. Instead, it is becoming a real-time enabler of both speed and quality, embedding intelligence throughout the entire manufacturing process. At Hexagon, we believe metrology is the bridge that allows aerospace manufacturers to accelerate production without compromising quality.

We have seen this in action:

· Our technology touches 90% of all aircraft

· More than 100 leading commercial aircraft are measured by our trackers each month

· In aerospace, we have seen customers reduce their inspection time by 75%

Data-driven manufacturing: the end of guesswork

For the vast majority of time since the advent of industrial manufacturing, quality assurance was reactive. We inspected part after production, and defects led to costly rework or scrap. This delay not only slowed down production but also resulted in significant waste. Now, manufacturers are shifting to proactive, in-process measurement and analysis, powered by digital twins, real-time sensors, and AI-driven automation.

Rather than react to problems after they occur, aerospace manufacturers can embed quality at every stage of the product lifecycle. This requires more than tools. It requires a data-driven mindset, empowered by digital thread integration, smart metrology, and simulation-driven design validation.

Real-time quality insights enable:

· Faster design iterations

· Reduced scrap and rework

· Automated, consistent inspections

· Shorter time to certification

· Lower environmental impact through less waste

Automating accuracy: faster production, higher precision

Metrology no longer needs to slow down the process—it can enhance it. With automated inspection and AI-powered software, manufacturers can achieve ultra-fast measurement cycles without human intervention.

By leveraging automated Coordinate Measuring Machines (CMMs), portable scanning solutions, and inline inspection systems, manufacturers can achieve real-time feedback on production performance. This means we can catch defects before they become costly problems, keeping the line moving and reducing waste. Some examples of technological accelerators include:

· Smart CMM programming allows rapid adaptation to new designs with minimal downtime.

· Laser scanning and structured light systems enable high-speed, non-contact measurements for even the most complex components.

· Integrated machine tool measurement ensures real-time quality checks on the CNC machine itself, reducing the need for separate inspections.

· Enhancing inspection hardware connectivity ensuring downstream processes that were once separate become fully integrated

This level of speed and automation removes the bottlenecks traditionally associated with quality control, allowing manufacturers to scale production efficiently while maintaining precision.

The role of digital twins in predictive quality

One of the biggest advancements resolving the speed vs. quality quandary is digital twin technology. By creating a virtual replica of a component or its production environment, manufacturers can simulate, predict, and optimise their processes before physical production begins, vastly reducing the chance of errors or quality issues.

For example, before we make an an aircraft component, Hexagon’s digital solutions allow engineers to:

· Simulate potential defects

· Adjust tool paths for maximum accuracy

· Validate tolerances virtually This proactive approach utilising a digital twin early in the process drastically reduces trial-and-error iterations, accelerates time-to-market, and enhances first-time-right manufacturing. In addition, a digital twin can be use simultaneously across different disciplines whereas a physical part can only be present in one place at any one time. Therefore it is more efficient in terms of direct cost and also in terms of empowering parallel workflows which in turn lead to shorter development cycles.

Overcoming the skills gap with intelligent metrology

As skilled workers retire, aerospace manufacturers face a growing talent shortage. Complex metrology systems often require extensive training, making it difficult for new workers to get up to speed quickly and maintain quality standards. Hexagon is addressing this challenge by making metrology hardware and software more intuitive and accessible:

· AI-powered software automates decision-making, reducing reliance on expert operators as well as speeding up processes.

· Augmented reality (AR) interfaces guide workers through measurement processes step by step.

· Cloud-based analytics ensure all teams have equal access to insights, eliminating silos and improving cross-departmental collaboration.

This human-centered approach to automation ensures both speed and quality without compromise.

A new era of manufacturing agility

So, the old trade-off between speed and quality looks like it is becoming obsolete. With Hexagon’s advanced metrology solutions, manufacturers can embrace both, simultaneously.

The future promises the potential to gain faster production cycles with automated, in-process inspection, benefitting from higher precision through AI-driven analytics and digital twins. These benefits extend to reduced waste and rework thanks to stronger ability to detect issues before they escalate later in the process. And as global business continue to encounter supply chain challenges, improved agility with smart, intuitive tools that empower a modern, connected workforce will be welcomed.

The landscape is changing for the better in aerospace, as manufacturers who harness these innovations will no longer have to choose between speed and quality. With metrology at the heart of digital transformation, they can have both.