Structural quality control of prefabricated parts and components is important to the weapon system assembly line. An effective and flexible Non-Destructive Inspection (NDI) tool for highly varying and diverse parts made of composite and metallic materials will help increase the rate of production and reduce the number of faulty weapons. Traditional Mon-Destructive Testing (NDT) methods, such as Ultrasound Testing (UT), X-ray, and Eddy Current (EC), have difficulties in detecting micro-fractures in seams and joints when considering sensitivity, system portability, and Occupational Safety & Health Administration (OSHA) rules for electromagnetic radiation. IAI, and its collaborators from Lockheed Martin and Johns Hopkins University, will further refine, and test a portable, multi-modal, reliable and sensitive NDI tool (NEWS-SIR) for weapon system component assessment. The NEWS-SIR system can detect micro fractures and porosities in large-scale composite and metallic structures with complex geometries. It is more sensitive to micro-damages than any traditional ultrasonic system. NEWS-SIR enables a very high Probability of Detection (PoD) at high throughput, and allows fine characterization of small defects (such as microcracks and porosities) on or below the structure’s surface. The final prototype sensor hardware/software deliverable will be a low cost, effective way for NDI of manufacturing defects in seams and joints of the weapon system. The resulting technology can also be used as a diagnostic and quality assurance tool wherever complex sealed joints are used.