Client: Lufthansa Technik

Project: Reverse Thruster Repair – Fixture Design

Challenge

Repairing an aircraft’s reverse thruster isn’t just technical; it’s mission-critical. Lufthansa Technik required a custom fixture to safely position the thruster during the repair process. Traditional measurement methods posed risks of inaccuracy, misalignment, rework and costly delays. These are some serious challenges no airline can afford.

Our Solution

OTS introduced state-of-the-art 3D scanning technology to capture the thruster’s exact geometry and mounting points. From this, we built a high-fidelity digital twin: a precise virtual replica that became the foundation for fixture design, validation, and seamless integration.

Results & Benefits

• Perfect Fit, Every Time: fixture engineered with exact scan data, ensuring flawless alignment
• Zero Rework: eliminated costly misalignments and redesigns
• Streamlined Efficiency: digital precision accelerated fixture design and manufacturing, reducing repair timelines
• Higher Repair Standards: secure and accurate fixture placement enabled superior repair quality and reliability.

Impact
By combining digital precision with engineering excellence, OTS helped Lufthansa Technik accelerate repair cycles, reduce costs and enhance quality standards for critical aircraft components.

3D Scanning for Fixture Alignment