The Voliro T Drone: Fly, See, and Touch Your Energy Assets

Voliro T’s innovative tri-copter design-with two tiltable, independently pivotable rotors and a stabilizing third rotor-delivers true 360° omnidirectional freedom, enabling advanced industrial inspections that go far beyond the limits of conventional quadcopters.

Ask any energy and industrial asset owners whether they want safer, more efficient and more comprehensive inspections and the answer will be a resounding “yes!” Enter the Voliro T drone—a purpose-built aerial platform that not only flies and “sees” but also physically interacts with infrastructure. This novel aerial robot has created a new paradigm for asset integrity and uptime. This is the story of how Voliro, in partnership with Osprey Integrity, has redefined what drones can do for the energy sector.

Meet the Visionaries: Laurent Zimmerli and Courtland Penk

Laurent Zimmerli, VP Growth at Voliro, brings a unique blend of technical expertise and customer-centric vision to the drone industry. With a background in computer science and cybersecurity from ETH Zurich, Zimmerli has spent years translating cutting-edge technology into real-world business value. From software developer to leading customer experience and growth at Voliro, his passion for bridging the gap between innovation and practical application have defined his career.

Courtland Penk, Founder and CEO of Osprey Integrity, has a story equally rooted in transformation. A former commercial pilot, Penk shifted from aviation to industrial inspection after a career pivot, mastering non-destructive testing (NDT) methods like ultrasound and magnetic particle inspection. Seven years ago, he merged his expertise in flight and inspection to create Osprey Integrity, a drone service provider focused on heavy industry inspections across Canada and the United States.

Together, Zimmerli and Penk formed a partnership which exemplifies the fusion of advanced robotics and field-tested inspection know-how. 

The Voliro Origin Story: From Research to Real-World Impact

In 2016, what began as a research project at the Autonomous Systems Lab in the Federal Technical Institute, Zurich, spurred the creation of Voliro. At the time, the core challenge involved whether a drone could be designed to interact with surfaces and objects in a stable, controlled manner. 

Initially, the team had no fixed use case in mind, just this research prompt. However, once they cracked the code on “fly, see, touch,” they soon recognized the vast potential for a drone that could do more than just fly and observe. By 2019, the project spun out into a company, and the Voliro T’s foundational design was set. 

The next phase involved real-world testing and early adoption. Working with industrial giants like Shell, Petronas, and Holcim, as well as service providers like Osprey Integrity, the Voliro team experimented with tasks ranging from cleaning and grinding to spraying and drilling—essentially anything that could be done with a handheld tool. Voliro’s drone made all of these things possible at height…and without putting humans at risk.

The Evolution: From Concept to Energy Inspection Powerhouse

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Voliro T streamlines wind turbine lightning protection system inspections by making precise contact with blade receptors and measuring resistance in just 20–40 minutes per turbine. This safer, scalable process more than doubles the efficiency of traditional methods.

The company launched the Voliro T drone in 2022, equipped with an array of sensors and payloads tailored for industrial inspection. The company quickly honed its focus on NDT—specifically, the ability to perform contact-based measurements such as ultrasonic thickness testing and lightning protection system inspections on wind turbines. (Previous AG coverage of Voliro’s NDT here).

The realization that many inspection tasks require not only visual data but also tactile feedback, something that traditional drones simply couldn’t deliver, drove this realization. The Voliro T’s unique design and payload versatility have since made it a preferred tool for asset owners and inspection service providers in sectors where downtime and safety remain paramount.

The Voliro T: Technical Marvel and Industry Workhorse

Unique Tri-Copter Design

Voliro T’s tri-copter architecture supports its unique capabilities. Unlike conventional quadcopters, the Voliro T features three rotors, two of which are tiltable and independently pivotable, while the third stabilizes and enables vertical movement. This configuration grants the drone true 360° omnidirectional freedom. This allows it to approach and interact with surfaces from any angle, including vertical, angled and even inverted positions.

Zimmerli explained: “The uniqueness is the design, and the design is done for a particular purpose… to interact with objects or surfaces, meaning applying pressure and force. The rotors can tilt independently of each other in any direction, so they can actually move the vehicle without tilting or moving the vehicle as such.”

Specifications at a Glance

The Voliro T’s impressive capabilities stem from its thoughtful engineering and design, honed to delivering precise, reliable results in challenging environments. Below is an overview of the key features that set the Voliro T apart from conventional aerial platforms:

FeatureSpecification/Capability
Rotor ConfigurationTri-copter, tiltable rotors for 360° maneuverability
Payload CapacityUp to 2.2 lbs (1 kg)
Flight Time10–15 minutes per mission
Contact ForceUp to 6.7 lbs (30 N) of stable force
SensorsDual 4K cameras, depth camera, six LiDAR, six velocity sensors, RTK GPS
Operating EnvironmentsGPS and GPS-denied environments
Sensor IntegrationPlug-and-play with a wide array of interchangeable payloads

Expanding Drone Capabilities: From Fly-and-See to Fly-See-and-Touch

Traditional drones have long been increasingly used for visual inspections, but their utility has been limited to what their cameras can capture from a distance. The Voliro T changes the game by enabling physical contact with assets, which allows for NDT measurements that require stable, precise force application. In other words, the drone’s advanced mobility and sensor suite enable it to not only “fly and see” but also “fly, see, and touch”—a significant leap forward in drone inspection technology. 

“We’re not just providing eyes in the sky, but also robotic hands, if you will, on the surface. This combination allows for a comprehensive assessment of asset integrity,” Zimmerli explained.

Penk reinforced the significance of this third dimension for inspections. “The ability to apply consistent force, regardless of the drone’s orientation, opens up new possibilities for inspecting complex structures,” he said. “It leads to more thorough and timely maintenance decisions.”

This capability is particularly valuable for assets with challenging geometries, such as domed, sloped, or irregular surfaces, where conventional methods would require costly scaffolding, rope access, or prolonged shutdowns.

Osprey Integrity: Putting Voliro T to Work

Osprey Integrity has been at the forefront of deploying the Voliro T across North America, leveraging its unique capabilities for clients in mining, oil and gas, power generation and manufacturing. 

Penk emphasized the importance of the drone’s versatility: “We’re looking to bring tools to our toolbox that we can in one visit… We can show up with a suite of tools, and be able to take on almost anything that we’re asked to achieve with respect to drone inspection capabilities today,” he noted.

Use Cases: Industrial and Energy Sector Applications

The Voliro T is more than just a technological marvel—it’s a practical tool with real-world impact across multiple sectors. Its unique ability to both observe and interact with complex structures has opened up new possibilities for inspecting, maintaining and safeguarding critical infrastructure. From renewable energy assets to heavy industry, the Voliro T continues to prove its value by making a measurable difference.

Wind Turbine Lightning Sensor Inspections

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Voliro T performs ultrasonic thickness measurements on stacks, storage tanks, boilers, silos, and overhead piping by pressing a probe directly against surfaces. This enables engineers to assess corrosion and plan maintenance with accurate, real-time data-without taking assets offline or exposing workers to hazardous heights.

The inspection of wind turbine lightning protection systems provides one of the most compelling use cases for the Voliro T. Wind turbines, often standing tall in remote or offshore locations, are “natural lightning magnets,” explained Zimmerli. Ensuring the continuity and integrity of their lightning protection systems is critical to prevent catastrophic failures and fires.

Traditionally, this inspection required technicians to climb towers and rappel down blades, manually testing each receptor—a time-consuming and hazardous process. With the Voliro T, the drone can press a needle against the blade’s receptor, complete the electrical circuit via a thin cable to the ground and measure resistance in as little as 20–40 minutes per turbine. This process is not only faster but also significantly safer and more scalable. It allows for 5–10 turbines to be inspected per day versus just 2 to 4 with traditional methods.

Ultrasonic Thickness Testing

Beyond wind turbines, the Voliro T excels at ultrasonic thickness measurements on industrial structures such as stacks, storage tanks, boilers, silos and overhead piping. By pressing an ultrasonic probe against steel or other materials, the drone can collect accurate thickness data. This helps engineers assess corrosion rates and plan maintenance without taking assets offline.

Penk noted, “The drone’s ability to easily access multiple areas of the tower without needing heavy machinery like JLGs (note: access equipment, including aerial work platforms and telehandlers) or man lifts is a significant safety improvement.” He continued, “This approach minimizes the risks associated with working at heights and using large, cumbersome equipment.”

Pulsed Eddy Current (PEC) Sensor: What’s New

A recent addition to the Voliro T’s arsenal is the Pulsed Eddy Current (PEC) sensor, which allows for wall loss and volume loss measurements through up to four inch thick insulation, without removing it. This provides a serious breakthrough for industries where insulated pipes and vessels are common because it eliminates the need for costly and labor-intensive insulation removal just to inspect underlying metal.

Penk described the impact of adding the PEC sensor to the Voliro T. “Now we have a way to do that without having to put somebody up there, remove insulation, then do thickness testing, then put your insulation back on and then do that all over again,” he explained.

Other Industrial Applications

Beyond wind turbines and ultrasonic testing, the Voliro T’s versatility makes it invaluable across a wide array of other industrial settings where safety, efficiency, and uptime are paramount. Here are a few other examples of how the Voliro T delivers measurable value:

  • Mining: Rapid inspection of critical ore processing equipment reduces planned repair scope and saves operators over $1 million (Canadian) in a single inspection.
  • Oil & Gas: Pre-turnaround inspections minimize shutdown time and optimize maintenance cycles.
  • Transmission Lines: Live-line inspections occur without taking the grid offline. This reduces risk and maximizes asset availability.
  • Steel Manufacturing: Can complete inspections of 100-foot towers in about one hour, as opposed to days using traditional methods, while improving safety and accuracy.

Zimmerli summed it up the return on investment across all use cases. “We’re reducing the need to expose people at height, while increasing the consistency of the data collected dramatically,” he said.

What’s Next for Voliro: From Sensing to Acting

Exciting news: the Voliro team has perfected sensing, but isn’t stopping there. Zimmerli revealed, “We slowly want to move over from what we call sensing to acting… We really want to make this move slowly but steadily…that’s the innovation. That’s what’s up next.”

Recent demonstrations have shown the Voliro T equipped with a gripper payload, capable of picking up and manipulating objects and hinting at future applications in light maintenance or repair tasks. As the platform continues to evolve, expect even more integration of advanced sensors and robotic tools to further expand the boundaries of what this drone can achieve in industrial environments.

The Voliro T Advantage In a Nutshell

The Voliro T drone stands as a testament to what’s possible when visionary engineering meets real-world industrial challenges. Its tri-copter design, 360° maneuverability and ability to “fly, see and touch” assets have reshaped how inspections are performed across the energy sector and heavy industry.

By reducing downtime, improving safety and delivering richer, more actionable data, potential users should not just consider the Voliro T as just another drone—it has become the new standard for asset integrity management. As Zimmerli and Penk’s partnership demonstrates, the future of industrial inspection belongs to those who can seamlessly blend technology, expertise and a relentless focus on solving real problems. And Voliro, with partners like Osprey Integrity, has clearly cracked that nut.

Watch Laurent Zimmerli and Courtland Penk on the Dawn of Autonomy podcast (Click Here)

Voliro-T ROI: Safety, Efficiency, and Cost Savings

  • Reduced Downtime: Inspections can be performed while assets remain in service. This minimizes lost production and associated costs.
  • Enhanced Safety: Eliminating the need for scaffolding, rope access, or man lifts dramatically reduces the risk to personnel.
  • Operational Efficiency: Faster inspections mean more assets can be covered in less time, and early issue detection leads to better maintenance planning.
  • Cost Savings: The drone lowers direct labor and equipment costs as well as avoids opportunity costs from unplanned downtime.