Automotive recalls are costly, not just in dollars, but in lost time, brand equity, and customer trust. For OEMs and Tier 1 suppliers under pressure to meet tight timelines while maintaining quality, the risks are high and the margin for error is thin. That is why more manufacturers are turning to nondestructive testing (NDT) to proactively catch defects before they leave the plant floor.
Our team specializes in NDT and NDE solutions that go beyond basic compliance. We help prevent recalls by identifying material flaws, weld defects, and dimensional anomalies early and at scale. Our facilities across the Midwest, including Detroit, Indianapolis, and Cincinnati, are designed for high-volume throughput with fast turnaround, giving manufacturers the data they need to take action quickly.
The Cost of a Recall and Why NDT Is Your First Line of Defense
In 2023, millions of vehicles were recalled due to preventable component failures, from brake system defects to faulty welds in chassis assemblies. A single failure in the field often triggers a full investigation across an entire production run, even if only a handful of parts are affected.
What if you could detect the exact defect before the part ever leaves the facility?
That is where NDT comes in. By identifying problems at the prototype or production stage, inspections can eliminate the need for post-market remediation and reduce the risk of systemic failure across thousands of components.
Precision Testing for the Most Critical Components
Our technicians inspect a wide range of safety-critical automotive parts including:
- Powertrain components
- Occupant safety systems
- Control arms and tie rods
- Heads, calipers, and master cylinders
- Electronic chips and overlays
- Supplemental Restraint Systems (SRS)
We work directly with OEMs and suppliers to establish tailored programs that align with your part designs, production timelines, and quality benchmarks.
Core NDT Methods for Automotive Integrity
We use a complete range of nondestructive testing methods, including:
- Ultrasonic Testing (UT) to detect subsurface and internal flaws in metal and composite parts
- Magnetic Particle Testing (MT) for surface and slightly subsurface discontinuities in ferromagnetic materials such as shafts and structural components
- Liquid Penetrant Testing (PT) to find surface-breaking flaws in non-porous materials like castings and forgings
- Computer Radiography (CR) and Digital Radiography (DR) for fast imaging of internal structures, welds, and features without damaging the part
For manufacturers working with advanced designs such as electric vehicle components or ADAS modules, Real-Time Radiography (RTR) and Eddy Current Testing (ET) are also available to detect complex failure modes.
Inspection Programs That Keep Production on Track
Acuren offers inspection programs built to match the speed of automotive production. Whether you are in prototype development or full production, our services include:
- First Article Inspections (FAI)
- Production Part Approval Process (PPAP) inspections
- 100 percent parts inspection for critical features or recurring issues
- Post-production statistical sampling
- Root cause investigations for engineering issues
Our network of high-capacity labs supports immediate scaling, helping manufacturers respond quickly to changing demands.
Speed and Accuracy Without Compromise
Speed is critical, but never at the cost of reliability. At Acuren, our state-of-the-art labs and electronic test reporting systems deliver inspection data fast enough for real-time manufacturing decisions. With over 80 materials engineers on staff, you gain access not only to data but to expert interpretation.
This allows OEMs and suppliers to act confidently, whether correcting an issue or releasing a part into full production. Our labs are optimized for volume, making us an ideal partner for line-side support, launch schedules, and emergency testing needs.
Containment and Response When It Matters Most
If your line faces a potential quality issue, Acuren provides third-party containment, sorting, and logistics services. This includes full warehousing, traceability, inspection, and reporting, supported by our engineering and testing teams. These services are essential for reducing production stoppages and quickly identifying systemic problems.
In combination with custom inspection plan development, failure analysis, and materials engineering, Acuren’s containment services ensure that issues are not only resolved but understood and prevented from recurring.
Why Acuren?
When product quality directly impacts safety, the cost of missing a flaw is too great. Acuren provides advanced NDT, metrology, and engineering support to help our automotive clients deliver safe, reliable components with confidence.
Learn more about our automotive solutions or explore our full range of services in inspection, engineering, and materials testing.
Ready to Prevent the Next Recall?
Whether you’re launching a new product or managing risk on the line, Acuren offers the technical strength and speed you need to stay ahead of costly failures. Contact our experts to build a proactive NDT strategy that supports your quality goals and protects your reputation.
