MAGFLY
The Challenge
Name:
Crack detection with multi-element ultrasound transducer
Domain:
NDT, Ultrasound
Challenge proposer:
Objectives:
- Design a multi-element ultrasound transducer concept for crack detection of tank walls and ship hulls suitable for use as a payload for drones in AUTOASSESS.;
- Perform tests to verify its applicability for crack detection in realistic conditions.
Challenge Addressed:
Conventional inspection of large steel structures often requires scaffolding, rope access or confined-space operations, making inspections expensive, time-consuming and potentially hazardous. MAGFLY addressed the challenge of maintaining reliable sensor contact while flying, achieving stable magnetic coupling and continuous surface tracking during inspection. The project also solved payload integration constraints by designing a lightweight, modular inspection system compatible with the ScoutDI 137 platform while preserving flight stability and manoeuvrability.
The Solution
Name:
MAGFLY – Drone-based Magnetic Flux Leakage (MFL) System for Crack Detection in Ship Hulls
Description:
MAGFLY developed an innovative drone-based inspection solution for ferromagnetic structures by integrating an ACFM (Alternating Current Field Measurement) sensor into the ScoutDI inspection drone. The project combined non-destructive testing technology, aerial robotics and a novel mechanical payload to enable safe, efficient and accurate crack detection on ship hulls, storage tanks and other large steel infrastructures. During the project, the complete system was integrated, validated and tested under representative operational conditions in Norway, demonstrating the feasibility of performing stable contact-based inspections without exposing inspectors to hazardous environments.
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.
Key Results Delivered:
The project successfully delivered a fully integrated aerial inspection payload including an ACFM sensing module, a spring-loaded preload mechanism, a Ball Transfer Unit (BTU) sliding system and a modular mechanical interface for the ScoutDI drone. Validation tests confirmed stable flight, continuous sensor contact, reliable magnetic coupling and successful inspection of representative steel samples containing cracks and corrosion. The project also produced an improved hardware iteration that is already being further developed together with ScoutDI for future commercial deployment.
Unique Value and Impact:
MAGFLY combines advanced non-destructive testing with aerial robotics to perform inspections that are safer, faster and more cost-effective than conventional methods. Unlike traditional drone inspections based only on visual imaging, MAGFLY enables direct contact-based crack detection using ACFM technology while maintaining stable interaction with the inspected surface. The solution has strong commercial potential for ship inspection, offshore assets, storage tanks and other industrial steel infrastructures where reducing downtime and improving inspector safety are critical.
Solution in Action:
During the final validation campaign at ScoutDI’s facilities in Norway, the integrated drone inspected representative metallic panels containing artificial defects, cracks and different corrosion levels. The system maintained stable flight while the BTU mechanism allowed smooth sliding over the surface, ensuring continuous sensor contact and reliable defect detection. The solution is intended for inspection companies, shipyards, classification societies and industrial asset owners requiring rapid inspection of vessels, tanks and steel infrastructures with minimal operational disruption.
The Solution 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.
Key Team Members:
The AUTOASSESS Experience
AUTOASSESS provided the ideal framework to collaborate directly with ScoutDI and validate the technology under realistic operational conditions. The programme enabled technical integration, testing infrastructure, expert feedback and international collaboration that significantly accelerated the maturation of the solution. It also facilitated the transition from a laboratory prototype towards a validated system with clear commercial potential and future industrial exploitation opportunities.
Testimonial
“Participating in AUTOASSESS has been an excellent opportunity to validate our technology alongside leading European partners. The programme allowed us to test our solution in realistic conditions, strengthen our collaboration with ScoutDI and significantly accelerate the path towards commercial deployment. We expect this cooperation to continue beyond the project, creating new opportunities for safer and more efficient robotic inspection solutions.”
Javier Labarda