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Breeze booths—enclosed, low‑pressure wind‑tunnel chambers used for aerodynamic testing of small‑scale models—must maintain structural integrity under cyclic loading and pressure differentials. Undetected micro‑cracks can propagate, leading to catastrophic failure and compromised test data. This paper presents a high‑quality, non‑destructive crack detection methodology that fuses ultra‑high‑resolution digital radiography, structured‑light 3‑D scanning, and deep‑learning‑based image analysis. Experimental validation on three commercial breeze‑booth models demonstrates detection of cracks as small as 30 µm with a false‑positive rate below 2 %. The proposed workflow reduces inspection time by 68 % compared with conventional ultrasonic testing while providing quantitative crack morphology metrics essential for predictive maintenance.

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