Effective inspector training in Non-Destructive Testing (NDT) must go beyond theory, offering hands-on, relevant experiences that reflect real-world challenges. This work introduces a powerful new feature within WavePro that enables the creation of customised exam files by injecting artificial defects into clean base results. Instructors can define defect type, location, depth, axial length, circumferential extent, and orientation, directly supporting adult learning principles such as experiential learning, relevance, and task-oriented instruction.

These tailored defect scenarios are analysed using the POGO finite element program developed by Imperial College. This program produces high-fidelity simulation data that mimics realistic ultrasonic responses. The resulting output files (pogo-hist) are visualised in WavePro, allowing inspectors to immediately engage with practical, scenario-based learning that mirrors the conditions they encounter in the field.

This approach supports immediate application by aligning closely with NDT professionals' real inspection tasks. By integrating simulation with active problem-solving, trainees build competence through direct interaction with defect signals, rather than passive observation. The result is faster skill acquisition, higher retention, and improved on-the-job performance. This tool is an impactful addition to any training program, enabling organisations to standardise and elevate the quality of inspector qualification and ongoing professional development.