Case Study: easyJet achieves 80% faster aircraft damage assessments with 3D Systems Geomagic Control X

easyJet Cuts Aircraft Damage Assessment Time by 80% with Geomagic Control X™

easyJet, a leading European low-cost airline operating nearly 300 Airbus aircraft across hundreds of routes, faced a persistent challenge: reducing costly Aircraft on Ground (AOG) time when airframes were damaged by hail, bird strikes, or other incidents. Traditional damage checks relied on manual tools and subjective judgments, making inspections slow, inconsistent, and difficult to document — increasing delays, repair costs, and operational disruption.

easyJet partnered with OR3D to deploy portable handheld 3D scanners and Geomagic Control X inspection software, enabling rapid, repeatable dent analysis on large surfaces without extensive training or CAD setup. The new workflow cut assessment time from days to hours (about an 80% reduction), delivered tens of thousands of pounds/euros in savings per event, produced consistent, traceable reports for better repair decisions, and improved long-term asset documentation.

easyJet

Andrew Knight

Fleet Structures Engineer