How Extended Reality (XR) Is Transforming Nondestructive Testing: Unlocking Unprecedented Accuracy, Efficiency, and Training for the Next Generation of Inspectors (2025)
- Introduction: The Convergence of XR and Nondestructive Testing
- Core Technologies: AR, VR, and MR in NDT Applications
- Key Industry Use Cases: Aerospace, Energy, and Infrastructure
- XR-Enhanced Training and Certification for NDT Professionals
- Real-Time Data Visualization and Remote Collaboration
- Benefits: Improved Accuracy, Safety, and Cost Efficiency
- Challenges and Barriers to XR Adoption in NDT
- Market Growth and Public Interest: 2024–2030 Forecasts
- Leading Innovators and Official Standards (e.g., asnt.org, asme.org)
- Future Outlook: The Next Decade of XR in Nondestructive Testing
- Sources & References
Introduction: The Convergence of XR and Nondestructive Testing
The integration of Extended Reality (XR)—an umbrella term encompassing Virtual Reality (VR), Augmented Reality (AR), and Mixed Reality (MR)—with Nondestructive Testing (NDT) is rapidly transforming industrial inspection and maintenance practices as of 2025. NDT, a critical discipline for ensuring the integrity and safety of infrastructure and components without causing damage, has traditionally relied on manual techniques and specialized equipment. However, the convergence with XR technologies is ushering in a new era of digitalization, remote collaboration, and enhanced data visualization.
XR’s application in NDT is driven by the need for improved accuracy, efficiency, and safety in sectors such as aerospace, energy, manufacturing, and civil infrastructure. By overlaying digital information onto real-world environments (AR), immersing inspectors in simulated scenarios (VR), or blending both (MR), XR enables technicians to visualize subsurface defects, access real-time sensor data, and follow guided inspection procedures hands-free. This convergence is particularly significant as industries face increasing complexity in assets and a shortage of experienced inspectors.
Recent years have seen major organizations and research institutions piloting and deploying XR-based NDT solutions. For example, NASA has explored AR for remote guidance in spacecraft maintenance and inspection, while Siemens has integrated AR into its industrial service offerings to support field technicians with real-time data overlays and remote expert assistance. The American Society for Nondestructive Testing (ASNT), a leading professional body, has highlighted XR as a key trend in its recent conferences and publications, emphasizing its potential to address workforce training and knowledge transfer challenges.
The convergence of XR and NDT is also supported by advances in hardware—such as lightweight AR headsets and high-resolution cameras—and software platforms that enable seamless integration with NDT instruments and digital twins. As of 2025, several industrial XR devices are certified for use in hazardous environments, further expanding their applicability in oil and gas, power generation, and chemical processing sectors.
Looking ahead, the adoption of XR in NDT is expected to accelerate over the next few years, driven by ongoing digital transformation initiatives, the maturation of 5G connectivity, and the increasing availability of standardized XR solutions. Industry stakeholders anticipate that XR will not only enhance inspection quality and safety but also enable new service models, such as remote audits and predictive maintenance, fundamentally reshaping the future of nondestructive testing.
Core Technologies: AR, VR, and MR in NDT Applications
Extended Reality (XR)—encompassing Augmented Reality (AR), Virtual Reality (VR), and Mixed Reality (MR)—is rapidly transforming nondestructive testing (NDT) practices across industries such as aerospace, energy, and manufacturing. As of 2025, the integration of XR technologies into NDT workflows is accelerating, driven by the need for enhanced visualization, improved training, and increased operational efficiency.
AR overlays digital information onto the physical world, enabling inspectors to visualize subsurface defects, measurement data, or procedural steps directly on components under examination. For example, AR headsets are being deployed in field inspections to provide real-time guidance and data visualization, reducing human error and inspection time. Companies like Microsoft (with HoloLens) and Lenovo are actively developing AR hardware and software platforms that support industrial NDT applications, including remote expert assistance and digital workflow integration.
VR, on the other hand, is primarily used for immersive training and simulation. NDT technicians can practice complex inspection procedures in a risk-free virtual environment, improving skill acquisition and safety. Organizations such as The American Society for Nondestructive Testing (ASNT) are promoting VR-based training modules to address the global shortage of qualified NDT personnel and to standardize competency across regions. VR also enables the simulation of rare or hazardous scenarios, which are otherwise difficult to replicate in real life.
MR combines elements of both AR and VR, allowing users to interact with both real and virtual objects. In NDT, MR is being explored for collaborative inspections, where remote experts can annotate live 3D views of equipment, guiding on-site technicians through complex evaluations. This is particularly valuable in sectors like nuclear energy and aerospace, where expert availability is limited and equipment is highly specialized.
Recent years have seen pilot projects and early deployments of XR in NDT by major industrial players. For instance, Siemens and GE are investing in XR-enabled inspection solutions to streamline maintenance and quality assurance processes. These initiatives are supported by advances in hardware (lighter, more robust headsets), software (AI-driven defect recognition), and connectivity (5G, edge computing).
Looking ahead, the outlook for XR in NDT is promising. As device costs decrease and interoperability improves, broader adoption is expected, especially in remote and hazardous environments. Standardization efforts by bodies like ISO and ASME are anticipated to further accelerate integration, ensuring safety and reliability. By 2027, XR is projected to become a core component of digital NDT strategies, fundamentally reshaping inspection, training, and maintenance paradigms.
Key Industry Use Cases: Aerospace, Energy, and Infrastructure
Extended Reality (XR)—encompassing Augmented Reality (AR), Virtual Reality (VR), and Mixed Reality (MR)—is rapidly transforming nondestructive testing (NDT) across critical industries such as aerospace, energy, and infrastructure. As of 2025, the integration of XR technologies is moving from pilot projects to operational deployments, driven by the need for enhanced safety, efficiency, and workforce training.
In the aerospace sector, XR is being leveraged to improve the accuracy and speed of NDT inspections on complex components such as turbine blades, fuselage structures, and composite materials. Major aerospace manufacturers and maintenance organizations are deploying AR headsets to overlay digital schematics and real-time sensor data onto physical assets, enabling technicians to identify defects and follow standardized inspection protocols with minimal error. For example, the use of AR-guided workflows has been shown to reduce inspection times and improve documentation accuracy, supporting compliance with stringent regulatory standards. Organizations such as NASA have explored XR for remote collaboration and training in NDT procedures, particularly for space-bound hardware where precision is paramount.
In the energy industry, particularly in oil & gas and nuclear power, XR is addressing the challenges of inspecting hazardous or hard-to-reach environments. Technicians equipped with AR devices can access live data from ultrasonic, radiographic, or eddy current testing equipment while maintaining situational awareness. This hands-free access to digital information enhances safety and reduces the likelihood of human error. Companies like Shell have piloted AR-based NDT solutions for pipeline and refinery inspections, enabling remote experts to guide on-site personnel in real time. The ability to record and replay XR inspection sessions also supports regulatory compliance and knowledge transfer as experienced inspectors retire.
For infrastructure—including bridges, tunnels, and transportation networks—XR is facilitating large-scale asset management and predictive maintenance. Municipalities and engineering firms are adopting AR and MR to visualize subsurface defects, corrosion, or structural fatigue detected by NDT methods. This visualization capability aids in prioritizing repairs and communicating findings to stakeholders. The American Society for Nondestructive Testing, a leading professional body, has highlighted the growing role of XR in training the next generation of NDT professionals, offering immersive simulations that replicate real-world inspection scenarios.
Looking ahead, the convergence of XR with artificial intelligence and IoT-enabled NDT devices is expected to further streamline inspection workflows, reduce costs, and address the skilled labor shortage. As standards bodies and industry leaders continue to validate XR applications, adoption is projected to accelerate across aerospace, energy, and infrastructure sectors through the late 2020s.
XR-Enhanced Training and Certification for NDT Professionals
Extended Reality (XR)—encompassing Virtual Reality (VR), Augmented Reality (AR), and Mixed Reality (MR)—is rapidly transforming training and certification processes for Nondestructive Testing (NDT) professionals. As of 2025, the integration of XR technologies into NDT education is accelerating, driven by the need for safer, more effective, and scalable training solutions in industries such as aerospace, energy, and manufacturing.
Leading organizations, including the American Society for Nondestructive Testing (ASNT), have recognized the potential of XR to address critical challenges in NDT training. Traditional hands-on training often requires access to expensive equipment, hazardous environments, and expert supervision. XR platforms, by contrast, allow trainees to immerse themselves in realistic simulations of inspection scenarios, practice complex procedures, and receive instant feedback—all without the risks or logistical constraints of physical setups.
Recent years have seen the deployment of VR-based simulators for ultrasonic, radiographic, and eddy current testing, enabling users to interact with virtual instruments and defect models. For example, the International Atomic Energy Agency (IAEA) has piloted VR modules for NDT training in nuclear safety, reporting improved knowledge retention and skill acquisition among participants. Similarly, major aerospace manufacturers are collaborating with XR technology providers to create AR-guided inspection workflows, where digital overlays assist trainees in identifying defects and following standardized procedures.
Certification bodies are beginning to adapt their assessment frameworks to accommodate XR-based practical exams. The ASNT has initiated research into the validity and reliability of XR-assisted certification, with early results indicating that virtual assessments can match or exceed traditional methods in evaluating candidate competence. This shift is expected to expand in the next few years, as XR platforms become more affordable and accessible.
Looking ahead, the outlook for XR-enhanced NDT training is highly positive. Advances in haptic feedback, AI-driven scenario generation, and cloud-based collaboration are poised to further enhance realism and scalability. By 2027, it is anticipated that a significant proportion of NDT professionals will undergo at least part of their training or certification through XR environments, supported by standards and best practices developed by organizations such as ASNT and the International Organization for Standardization (ISO). This evolution promises not only to improve workforce readiness but also to address the global shortage of qualified NDT personnel.
Real-Time Data Visualization and Remote Collaboration
Extended Reality (XR)—encompassing Augmented Reality (AR), Virtual Reality (VR), and Mixed Reality (MR)—is rapidly transforming real-time data visualization and remote collaboration in Nondestructive Testing (NDT) as of 2025. The integration of XR technologies is enabling inspectors, engineers, and decision-makers to interact with complex datasets and collaborate across distances with unprecedented efficiency and accuracy.
A key driver of XR adoption in NDT is the need for real-time visualization of inspection data. XR headsets and smart glasses now allow technicians to overlay live sensor data, such as ultrasonic or radiographic results, directly onto the physical asset under inspection. This spatial context reduces interpretation errors and accelerates defect identification. For example, Microsoft’s HoloLens 2 is being deployed in industrial settings to project 3D models and live data streams onto equipment, enabling hands-free access to critical information during inspections.
Remote collaboration is another area where XR is making significant strides. With global infrastructure aging and skilled NDT professionals in short supply, organizations are leveraging XR platforms to connect field inspectors with remote experts in real time. Through shared XR environments, remote experts can view exactly what the on-site technician sees, annotate live video feeds, and guide procedures as if present on location. Siemens and GE have both piloted XR-based remote support systems for NDT, reporting reductions in travel costs and faster resolution of complex inspection challenges.
The convergence of XR with Industrial Internet of Things (IIoT) is further enhancing real-time data visualization. Sensors embedded in assets stream data to cloud platforms, which is then visualized through XR devices. This integration allows for predictive maintenance and immediate response to anomalies detected during NDT. Organizations such as The American Society for Nondestructive Testing (ASNT) are actively promoting research and standardization in XR-enabled NDT workflows, recognizing the technology’s potential to improve safety and reliability.
Looking ahead to the next few years, the outlook for XR in NDT is robust. Advances in wireless connectivity (5G/6G), lighter and more ergonomic XR hardware, and AI-driven data analytics are expected to further streamline real-time collaboration and visualization. As regulatory bodies and industry groups develop guidelines for XR use in safety-critical inspections, adoption is likely to accelerate, making XR an integral part of the NDT toolkit by the late 2020s.
Benefits: Improved Accuracy, Safety, and Cost Efficiency
Extended Reality (XR)—encompassing Augmented Reality (AR), Virtual Reality (VR), and Mixed Reality (MR)—is rapidly transforming nondestructive testing (NDT) by enhancing accuracy, safety, and cost efficiency. As of 2025, leading industrial sectors such as aerospace, energy, and manufacturing are increasingly integrating XR into their NDT workflows, driven by the need for more reliable inspections and operational efficiency.
One of the primary benefits of XR in NDT is improved accuracy. XR overlays real-time data, 3D models, and sensor outputs directly onto physical assets, enabling inspectors to visualize subsurface defects and complex geometries with unprecedented clarity. For example, AR headsets can project ultrasonic scan results onto a component, allowing technicians to pinpoint flaws with millimeter precision. This capability reduces human error and supports more consistent decision-making, as demonstrated in pilot projects by major aerospace manufacturers and energy companies. Organizations such as NASA have explored XR for remote inspection and maintenance, reporting enhanced detection rates and reduced rework in critical systems.
Safety is another significant advantage. XR enables remote collaboration, allowing experts to guide on-site personnel through complex inspections without being physically present in hazardous environments. This reduces exposure to dangerous conditions, such as high radiation or confined spaces, and supports compliance with stringent safety regulations. In the nuclear sector, for instance, operators have used XR to simulate inspection procedures and train staff, resulting in fewer on-site incidents and improved emergency preparedness. The International Atomic Energy Agency (IAEA) has highlighted the role of XR in enhancing safety protocols for nuclear facility inspections.
Cost efficiency is realized through reduced downtime, optimized resource allocation, and minimized travel expenses. XR-based training modules allow technicians to practice NDT techniques in immersive virtual environments, accelerating skill acquisition and reducing the need for expensive physical mock-ups. Additionally, remote support via XR can decrease the frequency and duration of site visits by external experts, leading to substantial cost savings. Industrial leaders such as Siemens have reported measurable reductions in inspection times and maintenance costs after deploying XR solutions in their NDT operations.
Looking ahead, the adoption of XR in NDT is expected to accelerate, driven by advancements in wearable hardware, real-time data integration, and AI-powered defect recognition. As regulatory bodies and industry consortia continue to validate XR-enabled NDT methods, the technology is poised to become a standard tool for ensuring the integrity and safety of critical infrastructure worldwide.
Challenges and Barriers to XR Adoption in NDT
The adoption of Extended Reality (XR) technologies—including Augmented Reality (AR), Virtual Reality (VR), and Mixed Reality (MR)—in Nondestructive Testing (NDT) is accelerating, but several significant challenges and barriers remain as of 2025. These obstacles span technical, organizational, and regulatory domains, influencing the pace and scale of XR integration in critical industries such as aerospace, energy, and manufacturing.
A primary technical challenge is the integration of XR systems with existing NDT equipment and workflows. Many NDT processes rely on legacy hardware and proprietary software, making seamless data exchange and real-time visualization difficult. For example, while organizations like American Society for Nondestructive Testing (ASNT) are actively promoting digital transformation, the lack of standardized data formats and interfaces complicates the deployment of XR solutions across diverse inspection environments.
Another barrier is the accuracy and reliability of XR-assisted inspections. XR overlays must align precisely with real-world components to avoid misinterpretation of defects or measurement errors. Achieving this level of spatial accuracy requires advanced tracking, calibration, and sensor fusion, which are still evolving. Furthermore, environmental factors such as lighting, electromagnetic interference, and confined spaces can degrade the performance of XR devices, as noted in technical discussions by industry leaders like GE and Siemens, both of which are actively developing digital and XR-enabled NDT solutions.
Workforce readiness is another significant concern. NDT professionals require specialized training to effectively use XR tools, which differ substantially from traditional inspection methods. The transition demands not only technical upskilling but also a cultural shift within organizations accustomed to established practices. Initiatives by bodies such as ASME (American Society of Mechanical Engineers) are beginning to address these gaps through updated training programs and certification pathways, but widespread adoption will take time.
Data security and privacy also present challenges, especially in sectors handling sensitive infrastructure or proprietary designs. XR systems often rely on cloud connectivity and real-time data sharing, raising concerns about unauthorized access or data breaches. Regulatory frameworks for digital NDT, including those from International Organization for Standardization (ISO), are evolving, but clear guidelines for XR-specific risks are still emerging.
Looking ahead, overcoming these barriers will require coordinated efforts among technology providers, standards organizations, and end users. Advances in interoperability, device robustness, and workforce development are expected to gradually reduce adoption hurdles, but significant progress is likely to unfold over the next several years as the industry matures.
Market Growth and Public Interest: 2024–2030 Forecasts
The integration of Extended Reality (XR)—encompassing Augmented Reality (AR), Virtual Reality (VR), and Mixed Reality (MR)—into Nondestructive Testing (NDT) is rapidly gaining momentum as industries seek to enhance inspection accuracy, safety, and workforce training. As of 2025, the market for XR in NDT is experiencing robust growth, driven by the increasing complexity of industrial assets, the need for remote collaboration, and the ongoing digital transformation across sectors such as aerospace, energy, and manufacturing.
Key industry players, including Siemens, GE, and Shell, have begun piloting and deploying XR-based NDT solutions. These systems allow inspectors to overlay digital information onto real-world equipment, conduct virtual walkthroughs of inspection sites, and simulate defect detection scenarios. For example, Siemens has demonstrated the use of AR headsets for real-time guidance during ultrasonic and radiographic inspections, reducing human error and improving documentation. Similarly, GE has integrated VR modules into its NDT training programs, enabling technicians to practice complex procedures in immersive environments.
Public and private research organizations are also contributing to the field. The American Society for Nondestructive Testing (ASNT) has highlighted XR as a transformative technology in its recent conferences and technical publications, emphasizing its potential to address the shortage of skilled NDT professionals and to standardize inspection quality. Meanwhile, the National Aeronautics and Space Administration (NASA) has explored XR for remote NDT of spacecraft components, underscoring the technology’s relevance in high-stakes environments.
Looking ahead to 2030, the outlook for XR in NDT is highly optimistic. Industry forecasts anticipate a compound annual growth rate (CAGR) in the double digits for XR-enabled NDT solutions, as more companies invest in digital infrastructure and as XR hardware becomes more affordable and ergonomic. The adoption is expected to accelerate in regions with strong industrial bases, such as North America, Europe, and East Asia. Furthermore, regulatory bodies are beginning to recognize XR-assisted inspections as valid methods, paving the way for broader acceptance and standardization.
In summary, the period from 2024 to 2030 is set to witness significant expansion in the use of XR for NDT, fueled by technological advancements, workforce needs, and growing public and industry interest in safer, more efficient inspection practices.
Leading Innovators and Official Standards (e.g., asnt.org, asme.org)
Extended Reality (XR)—encompassing Augmented Reality (AR), Virtual Reality (VR), and Mixed Reality (MR)—is rapidly transforming the landscape of Nondestructive Testing (NDT) by enhancing visualization, training, and remote collaboration. As of 2025, several leading organizations and standards bodies are actively shaping the integration of XR technologies into NDT practices, with a focus on safety, reliability, and workforce development.
The American Society for Nondestructive Testing (ASNT) is the principal professional body in the United States dedicated to advancing NDT. ASNT has recognized the potential of XR in improving inspector training and competency assessment. In recent years, ASNT has hosted technical sessions and workshops on XR applications at its annual conferences, highlighting case studies where AR headsets and VR simulators are used for hands-on training and procedure rehearsal. These initiatives are expected to expand, with ASNT’s committees exploring the development of recommended practices and guidelines for XR-based NDT training and certification.
The American Society of Mechanical Engineers (ASME), a global leader in engineering standards, has also begun to address XR’s role in NDT. ASME’s standards development committees are monitoring the integration of XR tools for inspection and maintenance in sectors such as pressure vessels, pipelines, and power generation. In 2024 and 2025, ASME has organized webinars and technical panels discussing the validation and standardization of XR-assisted inspection workflows, with an outlook toward formalizing best practices in upcoming code revisions.
On the innovation front, major industrial technology companies are collaborating with NDT equipment manufacturers to deploy XR solutions. For example, Siemens and GE have piloted AR-guided inspection systems that overlay digital instructions and real-time sensor data onto physical assets, enabling less-experienced technicians to perform complex inspections with expert oversight. These systems are being evaluated for compliance with industry standards and are expected to see broader adoption as regulatory frameworks mature.
Internationally, the International Organization for Standardization (ISO) is tracking the evolution of XR in industrial applications, including NDT. ISO technical committees are considering the implications of XR for data integrity, operator qualification, and safety, with the possibility of new standards or amendments in the next few years.
Looking ahead, the convergence of XR and NDT is poised to accelerate, driven by ongoing collaboration between standards bodies, industry leaders, and technology developers. The next few years will likely see the publication of formal guidelines and the establishment of certification pathways for XR-enabled NDT, ensuring that these advanced tools are deployed safely and effectively across critical infrastructure sectors.
Future Outlook: The Next Decade of XR in Nondestructive Testing
The integration of Extended Reality (XR)—encompassing Augmented Reality (AR), Virtual Reality (VR), and Mixed Reality (MR)—into Nondestructive Testing (NDT) is poised to accelerate significantly through 2025 and into the next decade. As industries such as aerospace, energy, and manufacturing seek to enhance safety, efficiency, and data-driven decision-making, XR is emerging as a transformative tool for both field and laboratory NDT applications.
In 2025, several major industrial players and research organizations are actively piloting and deploying XR solutions for NDT. For example, Siemens has demonstrated the use of AR headsets to overlay real-time inspection data onto physical assets, enabling technicians to visualize subsurface defects and access digital twins during ultrasonic and radiographic testing. Similarly, Shell has reported the use of VR-based training modules for pipeline inspectors, reducing training time and improving procedural accuracy in hazardous environments.
The adoption of XR in NDT is being driven by several converging trends:
- Remote Collaboration: XR platforms are enabling remote experts to guide on-site inspectors in real time, reducing travel costs and expediting complex inspections. Organizations such as The American Society for Nondestructive Testing (ASNT) are actively exploring standards and best practices for remote XR-assisted inspections.
- Data Integration: XR devices are increasingly capable of integrating with NDT instruments, allowing inspectors to visualize sensor data, 3D models, and historical records in context. This is expected to improve defect detection rates and reduce human error.
- Workforce Development: As experienced NDT professionals retire, XR-based training and simulation are becoming essential for upskilling new technicians. Organizations like NASA have piloted VR environments for simulating complex inspection scenarios, enhancing both safety and competency.
Looking ahead, the next decade will likely see XR become a standard component of NDT workflows. Advances in wearable hardware, 5G connectivity, and AI-driven analytics are expected to further enhance the capabilities of XR systems. Regulatory bodies and industry groups, including International Organization for Standardization (ISO), are anticipated to develop new guidelines to ensure the reliability and safety of XR-assisted inspections.
By 2030, XR is projected to enable fully immersive, data-rich inspection environments, supporting predictive maintenance and real-time decision-making across critical infrastructure sectors. The ongoing collaboration between technology providers, industry leaders, and standards organizations will be crucial in realizing the full potential of XR in nondestructive testing.
