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 inspection system that uses ACFM technology to detect surface defects on ferromagnetic structures like ship hulls, offering a safer and more efficient alternative to traditional testing methods.
Description of the solution: MAGFLY introduces a new generation of aerial non-destructive testing (NDT) for ferromagnetic structures by leveraging ACFM Eddy Current technology to detect surface and near-surface cracks without the need for physical contact or coupling media. By integrating a commercial ACFM sensor into a drone-compatible mechanical structure, MAGFLY enables safe, repeatable, and efficient inspection of large steel surfaces such as ship hulls, storage tanks, and offshore assets.
The system consists of a lightweight stabilization and mounting unit that ensures a consistent lift-off distance and controlled sensor orientation, even over curved or uneven geometries. The ACFM sensor operates in near-contact mode, measuring perturbations in the alternating current field caused by surface-breaking defects. This approach allows reliable crack detection without the need for couplant gel, surface preparation, or precise sensor alignment, overcoming key limitations of ultrasonic systems in aerial inspection scenarios.
MAGFLY is optimized for integration with industrial UAV platforms, maintaining a total payload below 500 g. Sensor data are transmitted to an external acquisition and processing unit, enabling real-time visualization as well as detailed post-flight analysis.
Developed by Seerstems Robótica y Sistemas S.L., a company specialized in robotic inspection and NDT automation, MAGFLY features a modular design that allows adaptation to multiple industrial contexts, including maritime structures, storage tanks, and wind energy assets. Fully aligned with AUTOASSESS objectives, the solution supports autonomous, standardized, and safe inspection operations, reducing risks for human operators and paving the way for predictive maintenance strategies 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
