NDT: What Managers and Engineers Need to Know (But Are Rarely Taught)

Ed Korkowski
May 25
2 min read

Most managers and engineers working in manufacturing, energy, or aerospace will interact with nondestructive testing (NDT) at some point. Yet many don’t realize what it actually takes to inspect a component—or how NDT choices affect cost, safety, and success.

This article isn’t about how to perform NDT. It’s about what leaders and designers need to understand so their teams can design better, manage smarter, and avoid costly surprises.

🔍 What is NDT, Really?

Nondestructive testing refers to any method that evaluates a material or component without damaging it. Eddy current testing, ultrasonic testing, radiography, and magnetic particle inspection are just a few tools in the NDT toolbox.

But here’s the catch: NDT doesn’t fix design flaws—it only reveals them.

If a part is hard to inspect, no amount of technician skill can save you.

🚧 What Managers and Engineers Get Wrong (And Why It Costs Them)

Designing Parts Without Inspection in Mind. Probes need access. Geometry affects signals. Coatings, burrs, and fasteners can block detection. If the part can’t be inspected, defects can’t be ruled out—leading to scrap, rework, or worse.
Assuming 'Pass/Fail' is Enough. Some flaws don’t mean immediate failure—but they might limit fatigue life or violate design criteria. Engineers need to understand fracture mechanics and probability of detection (POD) to interpret NDT reports correctly.
Requesting the Wrong Test for the Job. Not all methods detect all flaws. Eddy current might miss a deep internal crack. Radiography might miss a fine surface defect. Don’t just say “Do NDT”—consult early to choose the right method.
Waiting Too Long to Involve the NDT Team. When NDT is treated as a last-minute checkbox, results are poor. Smart teams involve NDT experts during design reviews, tooling decisions, and process qualification.

📊 What You Should Know to Lead or Design Effectively

✅ Which flaws matter? Learn basic fracture mechanics✅ Where are inspections performed? Think probe access and surface prep✅ What does success look like? Define criteria and flaw tolerance✅ What does '100% inspection' really mean? Understand its costs and tradeoffs✅ How long does inspection take—and why? Know the labor, complexity, and risk

🧩 How to Work Smarter with Your NDT Team

Ask early: “Can this be inspected reliably?”
Involve Level III experts in planning, procedures, and acceptance criteria
Don’t assume perfection—NDT has detection limits
Support proper calibration and training—results are only as good as the process
Invest in automation when scale or consistency matters.

💬 Final Thought

If you're a manager or engineer who works with NDT—but not in it—your understanding shapes whether it succeeds or fails. NDT is a silent safety net for your product, your customer, and your bottom line.

Want to dig deeper into how NDT fits into engineering, manufacturing, or safety programs?

👉 Visit eddycurrent.com — your one-stop source for technical guidance, eddy current training, and solutions that work across industries.