Disposable sensor inlays detect drilling errors the instant they happen. 100 ms alarm, sub-0.1 mm accuracy, zero FOD. The only solution that prevents — not just detects.
Working lab prototype with deterministic breach detection. No AI, no cameras — physics-based and fail-safe.
Cameras, laser trackers, and NDT systems inspect holes after they're drilled. None of them prevent the damage in real time. The problem is invisible until it's too late.
The system maps precise safe zones for every allowed fastener hole. Any drill breach outside these zones triggers an immediate alarm with exact location — stopping errors before they become structural defects.
This capability directly addresses one of the most expensive failure modes in composite and metallic assembly.
A thin, disposable sensor inlay sits behind the drill jig. After drilling, it is removed — zero weight, zero FOD added to the aircraft. Physics-based, deterministic detection with no AI tuning risk.
Breach outside the allowed window triggers an instant alarm with exact location at sub-0.1 mm resolution.
Deterministic trace-grid interruption. No AI, no cameras, no lighting dependency. Fail-safe by design.
Temporary manufacturing aid removed after drilling. Nothing left on the aircraft — no certification required.
Safe zones pre-mapped for each allowed fastener hole. Correct holes break only expected traces.
20–30 second setup. Single edge connector into station cable. Supports 4–8 inlays per station.
Rugged control box logs every drilling event. Optional lockout capability for safety-critical operations.
Sensor inlay positioned behind the drill jig, aligned to structural component.
Drill penetrates outside safe zone — instant alarm + precise fault location.
Operator corrects immediately before damage propagates. Prevention, not rework.
Inlay removed after drilling. Aircraft remains unchanged. Zero FOD, zero weight.
6–10 week payback for Tier-1 suppliers. $7.6M annual loss reduced to under $1.1M implementation cost.
Temporary manufacturing aid only. Nothing permanent on the aircraft — eliminates certification overhead.
Classified as tooling, not a flight-certified part. Shop-floor qualification — similar to drill jigs and fixtures.
Same architecture extends to nuclear, subsea, defence, and satellite applications.
| Technology | Prevents? | Real-Time? | Composites? | Zero FOD? |
|---|---|---|---|---|
| Cameras / AI | No | Sometimes | Limited | Yes |
| Laser / NDT | No | No | Yes | Yes |
| Infra SSR MRO | Yes ✓ | 100 ms ✓ | Yes ✓ | Yes ✓ |
Composite usage in new aircraft platforms is accelerating, increasing the volume of precision drilling operations.
OEMs face increasing pressure on quality and traceability. Prevention tools with measurable ROI are actively sought.
Tooling classification enables rapid deployment without aircraft recertification cycles — fast time-to-revenue.
The same physics-based sensor technology extends naturally to high-precision manufacturing sectors such as firearms production, defence, and critical infrastructure — offering multiple future revenue streams beyond the aerospace beachhead.
Developed working prototype and complete technical architecture from concept through lab validation. Patent application in preparation (filing targeted Q2 2027). Targeting first paid pilots ahead of MRO Middle East Dubai 2028. Seeking experienced aerospace advisor post-raise.
Working prototype demonstrated. Pre-seed deck available. Let's talk.