The US Air Force is interested in improving methods to quickly and effectively assess aircraft damage that occurs during routine training, combat and maintenance activities. Demanding operational tempos require near real time assessment of aircraft operational status. Though partially automated health assessment systems have been integrated into daily maintenance routines, many inspections are still conducted manually. Current methods for inspecting aircraft engine inlet and exhaust cavities are labor intensive and error prone. Airmen crawl into ducts looking for defects, trace suspected sites on Mylar sheets, note their position relative to cavity features, and manually enter the data into an aircraft assessment system. Technology that can reduce inspection times and eliminate sources of human error will benefit the Air Force by significantly increasing aircraft reliability and availability while reducing lifecycle maintenance costs. To address this critical need, IAI and its collaborator, EDGE Product Development have been awarded a new contract entitled, “AUTO-SCAN: Inlet and Exhaust Damage Registration Sensor.” AUTO-SCAN will automatically detect, characterize and register defects in the inlet and exhaust coating. It will capture the defect characteristics, orientation and location relative to the aircraft coordinate system. First, the feasibility of the AUTO-SCAN concept will be demonstrated through the design, development and testing of a prototype. Next, the AUTO-SCAN system will be developed to TRL/MRL 7 maturity and integrated with current aircraft health assessment systems. AUTO-SCAN will be portable, quick and easy to set up and tear down and suitable for flight-line environment. It can be used in legacy and emerging fighter aircraft as well as in private and commercial aerospace sectors.