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The Engineer’s Guide to Drone Manufacturing Defects

February 16, 2026

Drones pack high energy batteries, dense electronics, and lightweight structures into assemblies that see vibration, thermal cycling, and real load cases from day one. Many of the highest-risk failure modes stay buried inside closed components, so external inspection and destructive sampling miss the defects that drive yield loss and in-field resets. This white paper lays out where industrial CT fits into drone manufacturing, from pouch cell inspection and hidden solder joints to motor alignment, propeller integrity, and bonded composites.

Download this white paper and learn how to:

  • Inspect lithium-ion pouch cells and modules for deformation, layer misalignment, debris, and tab weld defects before they become thermal and reliability risks
  • Verify hidden solder joints in BGAs and QFNs inside fully assembled electronics, including voiding, bridging, and misalignment that can pass incoming checks
  • Confirm cable routing, pinched wires, and connector seating inside closed airframes, without teardown and without losing the evidence
  • Measure internal motor and rotor geometry, including shaft straightness, bearing seating, and concentricity that drive vibration and performance drift
  • Detect internal cracks, voids, and thickness variation in propellers, then quantify defect severity with repeatable measurement workflows
  • Evaluate bond lines and composite structures for internal discontinuities and delamination that surface late in testing or after shipment

Download the full paper to see how drone teams use CT to expose hidden defects early, shorten investigations, and keep inspection aligned with fast design changes and production schedules.

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