To improve the accuracy of dimensional x-ray computed tomography (CT), error sources have to be characterised and accounted for. A variety of error sources have been comprehensively described in the literature. However, the influence of geometrical distortion of the flat-panel detector has rarely been considered. In this paper, the deviation from nominal geometry of a flat-panel x-ray detector was characterised using a calibrated ball plate. In-plane deviations were separated from the detector topography by varying the source–detector distance, resulting in a 3D detector geometry. A correction model for arbitrary source–detector distances was developed, which reduced the maximum errors of sphere centre-to-centre distances in scale-corrected CT measurements from  ±3.9 µm to below  ±0.8 µm. This fivefold improvement emphasises the importance of such correction for dimensional CT.

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