Building a Cad-Native Digital Twin for Ndt and Plm: Workflow, Tools, and Case Study

Abstract Digital twins (DTs) can connect inspection data with product models to support safer, more efficient lifecycle decisions. This paper proposes a CAD-native workflow for implementing a digital twin that visualizes and manages non-destructive testing (NDT) results directly on a 3D model. The method supports over-the-surface data (ultrasonic C-scans, UT) via UV mapping and projected images (thermography, TT) via planar projection, both executed in Siemens NX with custom macros for point localization and on-surface measurement. We validate the approach on a bottom nacelle panel from a Honeywell HTF7000 turbofan engine, acquired via 3D scanning and reverse engineering. The resulting digital twin preserves a persistent spatial link between inspection images and geometry, enables remote sizing and review, and centralizes result management in the CAD environment for PLM use cases (e.g., defect history, trend analysis). Timelines indicate higher initial effort but reduced on-site workload and travel for qualified inspectors thereafter. Limitations include large file sizes when storing geometry and multiple images in a single model; we outline a lightweight distribution strategy and future automation/VR enhancements. The findings demonstrate the feasibility and practical value of CAD-resident digital twins for NDT visualization, remote evaluation, and product lifecycle management.