Drone-Based Non-Destructive Testing (NDT)

Drone-based non-destructive testing (NDT) represents a transformative approach to asset inspection and maintenance. By integrating cutting-edge aerial robotics and advanced NDT technologies, such as ultrasonic transducers and pulsed eddy current sensors, these systems ensure safe, efficient, and precise testing across industries. From inspecting critical infrastructure to monitoring structural integrity, drone-assisted NDT platforms are reshaping the way inspections are performed, offering unparalleled accuracy and efficiency in even the most challenging environments.
Overview Drone-Based Non-Destructive Testing (NDT)
By Staff Writer Last updated: January 30th, 2025

What is Drone-Based Non-Destructive Testing?

Non-destructive testing (NDT) is a suite of techniques used to evaluate the integrity of materials, components, or structures without damaging them. Drone-based NDT combines this technology with unmanned aerial vehicles (UAVs), leveraging their ability to navigate challenging or hazardous areas. By mounting specialized NDT sensors and tools onto drones, operators can conduct detailed inspections of critical assets such as powerlines, wind turbines, pipelines, and offshore structures, reducing risks and improving operational efficiency.

Drone-based NDT eliminates the need for scaffolding, cranes, or manual inspections in hard-to-reach locations. Instead, drones equipped with advanced sensors, such as ultrasonic transducer thickness gauges, pulsed eddy current (PEC) testers, and electromagnetic acoustic transducers (EMAT), perform precise measurements while capturing high-resolution visual and thermal data.

Key Technologies in Drone-Based NDT

Drone-based non-destructive testing leverages a sophisticated array of advanced tools and sensors to revolutionize aerial inspection capabilities. By combining high-precision measurement technologies with the maneuverability and reach of drones, these systems provide comprehensive insights into the structural integrity of critical assets. Each tool is designed to address specific inspection challenges, enabling detailed evaluations in environments that are often hazardous, hard to access, or time-intensive for manual methods. These cutting-edge technologies ensure enhanced efficiency, safety, and accuracy in asset integrity management. They include the following:

Aerial Inspection PEC Payload

PEC Drone Payload by Voliro

Pulsed Eddy Current (PEC) Sensors

PEC technology is vital for detecting corrosion under insulation and other surface defects. Mounted on inspection drones, PEC sensors enable fast, accurate measurements of material thickness and corrosion levels without direct contact.

Lightning Protection System Testers

These testers ensure the integrity of lightning protection systems on tall structures like telecom towers and wind turbines. Using drones, inspectors can quickly assess systems for wear or damage without requiring technicians to climb hazardous heights.

Ultrasonic Transducer Thickness Gauges

Ultrasonic thickness gauges, available in high-temperature, standard, and electromagnetic acoustic transducer (EMAT) variants, measure the material thickness and detect subsurface flaws. Automated drone inspections equipped with these tools can assess pipelines, storage tanks, and other critical infrastructure with unparalleled accuracy.

Dry Film Thickness Measurement

Dry film thickness gauges evaluate protective coatings and ensure compliance with safety and performance standards. Drone-assisted measurement reduces downtime and increases safety in industrial settings.

non-destructive testing inspection drone
Voliro T Non-Destructive Testing Inspection Drone

Applications of Drone-Based Non-Destructive Testing

Drone-based NDT has proven essential in a variety of industries, including:

Powerline and Utility Inspection

Equipped with thermal imaging and precision measurement tools, inspection drones efficiently assess powerlines, detecting corrosion, wear, and structural weaknesses.

Wind Turbines and Renewable Energy

Drones can inspect wind turbine blades and lightning protection systems, ensuring optimal performance and preventing costly repairs.

Oil, Gas, and Petrochemical Facilities

Ultrasonic and PEC sensors enable accurate testing of pipelines, tanks, and offshore platforms, identifying potential leaks or structural weaknesses early.

Infrastructure and Construction

From bridges to high-rise buildings, drone-based NDT ensures structural integrity while minimizing inspection time and costs.

Solar Farms

Drones use thermal imaging cameras to help identify malfunctioning panels, optimize energy production, and reduce maintenance costs.

Benefits of Drone-Based Non-Destructive Testing

The adoption of drone-based NDT offers several advantages over traditional inspection methods:

  • Increased Safety – Drones eliminate the need for human inspectors to operate in dangerous environments, such as extreme heights or hazardous areas.
  • Enhanced Accuracy – Advanced sensors and automated data collection ensure consistent and precise measurements across assets.
  • Cost and Time Efficiency – Drone inspections reduce operational downtime and the costs associated with manual inspections or extensive scaffolding setups.
  • Environmental Adaptability – Aerial robotics can operate in harsh conditions, including high winds, extreme temperatures, and confined spaces.

Drone Inspection Services and Providers

The growing demand for drone-based NDT has led to the development of specialized drone inspection services. Providers can offer state-of-the-art aerial NDT platforms designed to perform advanced ultrasonic, PEC, and lightning protection system tests with minimal human intervention. These drones are engineered to operate in demanding industrial environments, providing high-precision data collection for asset integrity management.

Products (7)

PEC Payload

Pulsed Eddy Current payload for Voliro T drone (coming soon)

Pulsed Eddy Current payload for Voliro T drone (coming soon)
...the first-ever drone enabled Pulsed Eddy Current payload developed by our 3rd party partners –...
Voliro T UAS

Advanced drone platform for non-destructive testing & contact inspection

Advanced drone platform for non-destructive testing & contact inspection
...ecifically for non-destructive testing and inspection applications, enabling asset owners and...
EMAT Payload

Electromagnetic acoustic transducer thickness gauge for Voliro T drone

Electromagnetic acoustic transducer thickness gauge for Voliro T drone
The EMAT (electromagnetic acoustic transducer) thickness gauge payload for the Voliro T UAS is ideal...
UT Payload

Ultrasonic transducer thickness gauge for Voliro T drone

Ultrasonic transducer thickness gauge for Voliro T drone
... using a water-based gel as a couplant. Compliant with EN 12668-1 and ISO 16831:2012, it is suitable...
High Temp UT Payload

High-temperature ultrasonic transducer thickness gauge for Voliro T drone

High-temperature ultrasonic transducer thickness gauge for Voliro T drone
The High-Temperature UT (ultrasonic transducer) thickness gauge payload for the Voliro T UAS is idea...
DFT Payload

Dry film thickness sensor for Voliro T drone

Dry film thickness sensor for Voliro T drone
The DFT (dry film thickness) gauge payload for the Voliro T UAS is ideal for inspecting protective c...
LPS Payload

Lightning protection system tester for Voliro T drone

Lightning protection system tester for Voliro T drone
...ed to a ground-based unit that features a cable management system, as well as an ohmmeter that is...

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