Performs a contact thickness measurements from the safety of the ground in confined spaces. The Elios 3 UT Payload is a specialized drone accessory that integrates a laser-based ultrasonic testing (UT) system onto the Elios 3 inspection drone. It is used to remotely measure material thickness and detect corrosion in inaccessible industrial assets. This payload is essential for quantifying defects and monitoring corrosion rates without requiring high-risk human entry or scaffolding.
UT” stands for Ultrasonic Testing, an NDT technique used to inspect materials, detect flaws, or measure thickness using ultrasound without damaging the object being tested. The UT Payload is a module designed as a collaboration between Cygnus Instruments and Flyability. It is mounted on the Elios 3 drone and is used to perform ultrasonic testing. UT is not a simple technique and requires the correct training and understanding of the technology and its outputs. Supplier: Flyability SA
The Elios 3 UT Payload unlocks a new frontier — thickness measurements taken from the air, in places where ladders, scaffolding, and rope access used to stand in the way. Developed alongside Cygnus Instruments, it turns the Elios 3 into a flying ultrasonic gauge that delivers accurate thickness readings supported by high-resolution A-scans, even in harsh and confined spaces. What once took hours of setup and risk can now be achieved in minutes — reducing downtime, improving safety, and delivering repeatable inspection data.
Precise, Location-Tagged UT Measurements
When used together with the LiDAR payload, every UT reading is anchored to its exact position on a live 3D model. This allows inspectors to see where every measurement was taken in real time, track inspection coverage, and visualize results directly on a digital twin. Combined with the Asset Management software extension and Cockpit’s Live Map, spatial context becomes as clear as the data itself.
Smart Couplant Dispenser
The payload includes a remotely operated couplant dispenser that delivers just the right amount of gel for optimal ultrasound transmission. The operator can monitor remaining couplant and return for a quick refill or syringe swap when needed — no guesswork, no waste.
Smart Probe Arm
Designed specifically for drone-based UT inspections, the articulated probe arm intelligently positions the transducer onto the surface — adapting to contact angles, structures, and surface conditions — making reliable measurements possible in areas normally out of reach.
Modular Probe Head System
The UT payload supports interchangeable twin-crystal piezo-composite probes in 2 MHz, 5 MHz, and 7.5 MHz, making it effective on everything from thin pipes to thick, corroded steel. Echo-Echo capability lets you measure through up to 1 mm of coating without removing paint. Probe hoods are available to match different surface shapes, helping maintain optimal contact during flight.
Cleaning Module for Surface Prep
For surfaces covered in debris, dust, or corrosion, the probe head can be replaced with a cleaning module. Clean, tag the location, then return with the probe to perform measurement without losing precision or position.
Live A-Scan in Cockpit
On the operator’s screen, the Live A-Scan widget provides real-time UT displays with adjustable gain and gates, allowing both automated or manually refined readings — perfect for challenging surfaces, irregular coatings, or verification during flight.
Advanced Post-Processing
After the mission, Inspector 5 software turns captured UT data into actionable insights — allowing you to review, validate, analyze, and report with speed and clarity.
Built on Proven Technology
Developed in partnership with Cygnus Instruments, a pioneer in ultrasonic thickness measurement, the Elios 3 UT Payload brings decades of expertise directly into the air — merging trusted data accuracy with modern aerial capability
An Ultrasonic Testing (UT) payload accessory for the Elios 3 drone used to measure wall thickness and detect corrosion at remote contact points in confined spaces.
| Feature | Specification |
|---|---|
| Probe type | Dual element transducer (piezo-composite crystals) |
| Probe manufacturer | Cygnus Instruments |
| Measurement Range in Steel | 0.8mm to 250mm1 |
| Measuring Mode | Mode 2 (Single Echo) and Mode 3 (Echo-to-Echo) |
| Gain and Gate Control | Automatic or Manual Gain and Gate Control |
| Accuracy | ±0.1 mm (±0.004”) or 0.1% of thickness measurement whichever is the greatest |
| Resolution Display | 0.1 mm (0.005”) or 0.01 mm (0.0005”) |
| Calibration Mechanisms | Automatic V-path correction for twin crystal probes. Option of One or Two point calibration for twin crystal probes. |
| Gel acceptable viscosity | 1:1 mix of standard UT gel with water for optimal performance |
| Display | Dedicated UT tab in Cockpit with A-scan display |
| Certifications | RoHs, CE, FCC, FDA, IC (only for final MP) |
1. Value subject to change.
Modification from nominal specifications
| Flight time while hovering | 7min401 E3 + LiDAR Rev7 + UT with probe |
| Flight time in normal UT use (4 POM / Minute) | 7min2 E3 + LiDAR Rev7 + UT with probe |
1. Tests run at 0°C, 0% humidity, no wind, in ASSIST, Lighting by default (20W), new battery full capacity 98.8Wh, 100% to 0% on tablet (a margin of 10% is kept by the system).
2. Tests run at 20°C, 0% humidity, no wind, in ASSIST, Lighting by default (20W), new battery full capacity 98.8Wh, 100% to 0% on tablet (a margin of 10% is kept by the system).
Core module
Probe 2 MHz
Probe 5 MHZ
Probe 7.5 MH2
Cleaning module
Interfaces kit
Drone attachment kit
Extension kit
Gel kit
Spare smart syringe kit
SOFTWARE:
Cockpit integration
Inspector integration
SERVICE:
UT Online Training
**Dependent on the package chosen
UAV Thickness Sensor, Ultrasonic NDT Attachment, Aerial UT Probe
**Errors and omissions excepted (E&OE)
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