MRO inspection

Using a DJI NEO drone (assuming you meant DJI’s commercial drone platform such as the DJI Matrice 300 RTK with Zenmuse H20T/H20N payloads or similar) for a C-check inspection of an aircraft’s exterior is a viable and increasingly common method in aviation MRO (Maintenance, Repair, and Overhaul). Here’s how you can use it effectively:





✅ Objective:



Capture high-resolution, detailed images and video of the airplane’s external surfaces for inspection as part of the C-check (a comprehensive maintenance check done every ~20–24 months).





🔧 Pre-Flight Setup



  1. Permissions & Regulations
  3. Obtain clearance from airport authorities and aviation regulatory bodies (e.g., FAA, EASA, QCAA).
  4. Ensure you comply with drone flight regulations in airside areas.

  6. Drone Selection & Payload
  8. Use a DJI Matrice 300 RTK or similar industrial drone.
  9. Equip with a Zenmuse H20T (visual + thermal camera) or P1 camera for high-res photogrammetry.

  11. Flight Plan Configuration
  13. Use DJI Pilot or DJI Terra to define waypoints around the aircraft.
  14. Set altitude, overlap (70–80%), gimbal angle, and auto-capture intervals.
  15. Plan flights to cover:
  17. Fuselage
  18. Wings & flaps
  19. Empennage (tail)
  20. Landing gear
  21. Underside (with low-angle gimbal tilt)







🛫 Execution Steps



  1. Pre-flight Aircraft Prep
  3. Ensure aircraft is parked in a safe zone (hangar or ramp).
  4. Remove covers and unlock access panels if needed.
  5. Conduct visual inspection manually to guide drone areas of focus.

  7. Drone Launch and Navigation
  9. Perform full pre-flight checks (firmware, battery, GPS).
  10. Launch drone and follow the programmed flight path, or manual flight by a certified pilot if needed.
  11. Fly slowly (≤ 2 m/s) and close to the surface (1–2 meters where safe) for detailed captures.

  13. Capture Process
  15. Use 4K video and high-resolution stills.
  16. Utilize thermal imaging (if equipped) to detect overheating, fluid leaks, or insulation issues.
  17. Take oblique angles for rivets, seams, corrosion, cracks, and dents.






💻 Post-Flight Processing



  1. Image Review
  3. Use software like DJI Terra, PIX4D, or Agisoft Metashape to process into:
  5. Orthomosaics
  6. 3D models
  7. Annotation layers for defect marking


  10. Integration with MRO Software
  12. Export annotated images and maps into TRAX, AMOS, or Ramco Aviation MRO platforms.
  13. Create an inspection report with geotagged image evidence.

  15. AI-Powered Defect Detection (optional)
  17. Run AI/ML models trained to detect:
  19. Corrosion
  20. Oil leaks
  21. Delamination
  22. Surface cracks







⚠️ Safety Considerations



  • No-fly zones around engines and avionics unless powered down.
  • Always have a visual observer (VO).
  • Maintain drone to aircraft clearance limits (usually ≥ 0.5 meters).
  • Avoid windy conditions; calibrate compass and RTK modules.






📌 Final Note:



C-checks are heavy maintenance tasks and drone-based inspections are best used to augment, not replace, certified AME (Aircraft Maintenance Engineer) visual inspections. They’re ideal for reducing time, increasing precision, and improving digital documentation.


If you’re setting up a program for drone-based inspections, I can also help with:


  • SOP templates
  • Data annotation frameworks
  • Integration with your current asset management tools



Would you like a diagram of the drone inspection flight path around an airplane?


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