Advancing UK Aerospace, Defence, Security & Space Solutions Worldwide
  • Home
  • /
  • Aerospace
  • /
  • Third Dimension launches GapGun countersink measurement solution

Aerospace

Third Dimension launches GapGun countersink measurement solution

Third Dimension haslaunched an all new countersink measurement solution for its GapGun range.

The first of its kind on the market, it can calculate the dimensions of a countersink hole to accurately predict the flushness of fasteners once fitted. What’s more, it can operate in real time on the production lines of aircraft, cars and vans, and also in the energy and marine markets.

Last year in the commercial aviation industry alone, 1481 planes were manufactured with a total estimated 296 million countersinks. The average requirement is to measure 5% of each aircraft’s 200,000 countersink holes, meaning 10,000 countersink holes would have to be measured for every commercial aircraft produced. Done manually, these checks rely heavily on the competencies of the operator and are extremely time consuming.

Advertisement
ODU RT

Dennis de Roos, Third Dimension’s Chief Sales & Marketing Officer, said: “If the hole for a rivet isn’t the right size, it will create severe quality problems, either at the time of production or more worryingly further down the line. Our new, patented system will help prevent these issues in just a couple of seconds, per measurement. For the first time, fastener flushness and countersink characteristics can be measured quickly and accurately, time and time again, with no possibility of operator error.”

The patent-protected GapGun Countersink Inspection System enables the prediction of fastener flushness much faster and more accurately than mechanical gauge, with the addition of a fully auditable data trail. Tolerance bands can be pre-set, the measurement is recorded against these and then the result can be read onscreen or automatically sent to a PC to enable comparison and analysis.

Countersinks are notoriously difficult to measure in the industry; one of the main challenges for manufacturers is finding a way that factors in how to calculate the centre of the hole. The Third Dimension solution addresses this with a specially designed standoff integrated into the sensor.

This enables the system to calculate this crucial point to quality check the dimensions of hole, before the fastener is fixed in place. The system is based on a single laser line to give the best possible signal quality and therefore accuracy. As opposed to other solutions on the market, multiple laser lines or bars of light produce reflections which degrade accuracy and reliability when measuring the curved inner surfaces of a countersink.

Advertisement
Amentum rectangle

Tolerances for flushness of fasteners vary, but sometimes allow a small amount of protrusion, and always allow under-flush – for example one manufacturer specifies a tolerance of +0.05/-0.18mm on the final fastener flushness. The GapGun countersink can predict the flushness within these tolerance bands on the most common fastener types.

The countersink solution is available to order now from Third Dimension or through its global network of distributors.

 

Advertisement
Nokia leaderboard
MP backs aerospace and defence sectors

Aerospace Defence

MP backs aerospace and defence sectors

2 October 2025

A Labour MP has backed the aerospace and defence sectors and wants them to be ‘as successful as possible’.

IFS appoints Mihita Podobnik as Chief People Officer

Aerospace Defence

IFS appoints Mihita Podobnik as Chief People Officer

1 October 2025

IFS today announced the appointment of Mihita Podobnik as Chief People Officer, succeeding Debra McCowan, who is stepping down from her role as Chief Human Resources Officer.

Bristol Airport breaks its monthly passenger record

Aerospace

Bristol Airport breaks its monthly passenger record

30 September 2025

Bristol Airport has reported its busiest month ever with more than 1.2 million customers using the Airport in August, with many travelling on more fuel efficient and quieter aircraft.

NPAS helps crackdown on hare coursing across county borders

Aerospace Security

NPAS helps crackdown on hare coursing across county borders

29 September 2025

The National Police Air Service (NPAS) has joined Cambridgeshire Constabulary, Essex Police and Hertfordshire Constabulary in a renewed, coordinated effort to tackle hare coursing and associated rural crime under Operation Galileo.

Advertisement
Amentum rectangle
Birmingham Airport employment scheme secures impressive results

Aerospace

Birmingham Airport employment scheme secures impressive results

29 September 2025

A Birmingham Airport (BHX) employment initiative for young care experienced adults has resulted in 50% of participants securing paid employment at the regional transport hub.

Windracers makes history with UK’s first international civil drone approval

Aerospace Defence Security

Windracers makes history with UK’s first international civil drone approval

26 September 2025

The UK Civil Aviation Authority (CAA) has today approved Windracers, a British civil and defence drone manufacturer, to conduct the UK’s first civil unmanned aerial system (UAS) international operation.

Advertisement
Amentum rectangle