RVmagnetics & Airbus: Sensing Mat for Aircraft Repair

How RVmagnetics and Airbus Are Rethinking Composite Aircraft Repair

When RVmagnetics and Airbus set out to address one of aviation maintenance’s persistent challenges, the result was a jointly developed sensing mat that replaces conventional thermocouples with an ultra-thin, reusable sheet built on RVmagnetics’ patented MicroWire technology. The goal: faster, more reliable out-of-autoclave (OOA) repair of composite aircraft structures.

The Problem with Current Repair Processes

Composite aircraft structures are increasingly common, but repairing them remains labour-intensive. Thermocouple-based monitoring requires multiple sensors, complex wiring, and significant setup time on large curved surfaces – creating friction for MRO teams at every repair cycle.

The sensing mat changes this by replacing an array of individual sensors with a single flexible sheet featuring multiple integrated measurement points and just one connection interface.

Key Capabilities

Real-time, multi-point monitoring of cure cycles and heat distribution is at the core of what the sensing mat does. The technical highlights:

• Up to 80% faster sensor installation in out-of-autoclave hot bonder repairs
• Rated up to 200°C, with performance validated across multiple thermal cycles
• Ultra-thin MicroWire sensors that flex and conform to complex double-curved surfaces
• Compatible with conductive and radiant heating technologies
• Single connection interface for all measurement points

The result is more uniform heat distribution, lower risk of air leakages, improved repair quality, and a significant drop in setup time for large composite surfaces.

From Manufacturing to Repair – and Everything in Between

The sensing mat is part of a broader vision. RVmagnetics’ MicroWire technology supports composite structures across their entire lifecycle: monitoring conditions during manufacturing, enabling structural health monitoring in service, and now improving the efficiency of repair operations – all without affecting the structural integrity of the composite material itself.

Dr. Pavol Lipovský, Tech Lead of RVmagnetics, explained:

“With our technology we empower our clients with capabilities covering the whole composite lifecycle – from monitoring manufacturing processes, allowing real-time in-situ structural health monitoring during use, up to the composite repair operations. Collaborating with Airbus has allowed us to validate this sensing mat in the relevant environment. We are proud to contribute to setting a new industrial standard for complex composite repair processes.”

TRL 5 Reached, Prototype Phase Next

Following successful validation in a representative operational environment at Technology Readiness Level 5 (TRL 5), RVmagnetics and Airbus are advancing toward the prototype stage, with industrialisation steps to follow.

About RVmagnetics

RVmagnetics is a deep-tech company developing the world’s smallest passive sensor. The company’s contactless sensing solutions enable real-time monitoring in extreme environments while maintaining full structural integrity of composite materials. RVmagnetics serves the aerospace, automotive, medical, energy, and defence industries.