Challenge being tackled: The MAGFLY solution responded to challenge number 4: crack detection with multi-element ultrasound transducer, proposed by ScoutDI. The goal was to design, prototype, and validate a drone-mounted Magnetic Flux Leakage (MFL) system for detecting cracks and surface anomalies in ferromagnetic structures such as ship hulls and tanks, minimising human intervention and eliminating the need for contact or coupling media.
Description of the solution: MAGFLY introduces a new generation of aerial non-destructive testing (NDT) for ferromagnetic structures, leveraging Magnetic Flux Leakage (MFL) technology to detect cracks and corrosion without physical contact. By integrating a commercial MFL sensor into a drone-compatible mechanical structure, MAGFLY enables safe and efficient inspection of large steel surfaces such as ship hulls, tanks, and offshore assets.
The system consists of a lightweight stabilisation and mounting unit that ensures consistent lift-off distance and magnetic coupling even over curved or rough geometries. The sensor operates in near-contact mode, detecting discontinuities in the magnetic field caused by surface or near-surface defects. This eliminates the need for couplant gel or precise transducer alignment, overcoming key limitations of ultrasonic systems in aerial applications.
The solution is optimised for integration with industrial UAVs such as the Flyability Elios series, maintaining a total payload below 350 g. It can detect microcracks from 0.5 mm in length, with a coverage width of up to 60 mm. Data from the MFL sensor are transmitted to an external acquisition unit for processing and analysis, supporting real-time visualisation and post-flight evaluation.
MAGFLY is being developed by Seerstems Robótica y Sistemas S.L., a company specialised in robotic inspection and NDT automation. The system’s modular design makes it adaptable to various industrial contexts, from maritime hulls to storage tanks and wind turbines. Fully aligned with AUTOASSESS objectives, MAGFLY enables autonomous, standardised, and safe inspection operations, reducing risks for workers and paving the way for predictive maintenance in the European maritime industry.
About the provider: Seerstems Robótica y Sistemas S.L. is a Spanish technology company specialised in the design and development of advanced robotic systems for industrial inspection and maintenance in challenging environments. Founded in 2019, Seerstems integrates mechatronics, AI, and sensor fusion to create autonomous aerial, terrestrial, and underwater platforms capable of operating in confined, hazardous, or hard-to-access areas. The company has successfully delivered R&D projects for major industrial clients such as ArcelorMittal, DuPont, TK Elevator, and CSEM, and has developed patented technologies for aerial non-destructive testing (NDT). With a strong focus on innovation, Seerstems contributes to the digital transformation of industrial inspection processes, enhancing safety, efficiency, and sustainability across sectors like maritime, energy, and infrastructure.
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The Team behind the scenes:
Javier Labarda – Technical Director
