Structural quality control of pre-fabricated parts and components in a weapon system assembly line is very important for increasing productivity and reducing flawed end products. An effective and flexible Non-Destructive Inspection (NDI) tool for highly varying and diverse piece parts made of composite and metallic materials will be very useful. Traditional NDT methods such as Ultrasound Testing (UT), X-ray, Eddy Current (EC) etc. have difficulties in detecting micro-fractures and voids in seams and joints when sensitivity, system portability, and Occupational Safety & Health Administration (OSHA) rules for electromagnetic radiation within the workplace are considered. IAI has been awarded a new contract entitled, “Portable, Multi-modal Nonlinear Elastic Wave Spectroscopy - Sonic IR (NEWS-SIR) System for Manufacturing Defects Characterization.” The proposed NEWS-SIR system can detect micro fractures and porosities in complex composite and metallic structures. It can scan over large-scale structures with complex geometries and will be much more sensitive to micro-damages than the most commonly used linear ultrasonic counterpart. The final prototype sensor hardware/software will be an effective and low cost way for the non-destructive inspection of manufacturing defects of seams and joints in the weapon system. The proposed technology will be useful commercially as a diagnostic and quality assurance tool wherever complex sealed joints are used.