Skygauge Robotics has completed a 1-year testing program with the Assistant Deputy Minister of Materiel demonstrating a new approach to corrosion repair on naval vessels that removes the need for personnel to work at height.
The program focused on evaluating aerial robotics not just for inspection, but for performing physical maintenance tasks directly on the ship. The results showed that Skygauge’s drone is capable of completing spot rust repair.
Corrosion detection is already well understood and supported by established programs. The more persistent challenge is access. Many of the areas where corrosion develops are difficult to reach and require specialized methods to service.
Today, technicians often rely on rope access, lifts, or temporary scaffolding to reach these locations. These approaches can be time-consuming and introduce safety risks, particularly when work must be carried out along large vertical surfaces or in exposed conditions. In some cases, more extensive maintenance may require drydocking, which removes the vessel from operation for extended periods.
As a result, the limiting factor in corrosion management is often not identifying where work needs to be done, but being able to perform that work efficiently and safely.
Skygauge’s platform was originally developed for ultrasonic inspection, but it differs from conventional drones in one important way: it is designed to maintain stable contact with surfaces, allowing it to replicate how inspection work is performed by hand.
This contact-based capability has already been deployed across a range of industrial applications. Through the Innovative Solutions Canada Program, Skygauge worked with ADM (Mat) to evaluate whether the same approach could be extended beyond inspection to include repair.
Given that surface preparation and coating both rely on controlled contact and applied force, this represented a logical extension of the existing technology.
Testing was completed in May 2025 following a 1-year evaluation period. During this time, the team focused on developing and validating a full workflow for spot rust repair using the drone.
This included the use of a bristle blasting system, developed in partnership with MontiPower1, to remove corrosion from the surface. Additional tools were tested for surface preparation, including nylon brushes for removing dirt and grime and cloth-based tools for solvent cleaning. The team also developed a roller-based coating system capable of applying a consistent and even finish.
Across these stages, the drone was able to replicate the key steps involved in manual corrosion repair. The outcome of the program demonstrated that this work can be performed using a drone.
The next phase of this work will focus on demonstrating consistency and repeatability, with the goal of meeting the Royal Canadian Navy’s coating standards across a range of conditions and applications. Proving that the system can deliver the same quality of surface preparation and coating over time will be a critical step toward operational adoption.
Phase-2 trials have now begun under a follow on contract with ADM (Mat) to demonstrate not just the feasibility, but consistent application over many corrosion locations.
Beyond this, there is a deeper opportunity emerging. Rather than being used only as a reactive tool for spot repairs, drones have the potential to become part of a proactive coating life extension program. By enabling faster and more frequent intervention in hard-to-reach areas, early-stage corrosion can be addressed before it spreads or requires more intensive maintenance.
This approach will help extend the lifespan of existing coatings, reduce the need for large-scale repair cycles, and limit reliance on drydocking. This is a paradigm shift from periodic, resource-intensive maintenance toward a more continuous and targeted model.
Skygauge Robotics is building a workforce in the sky. Unlike standard visual drones, the Skygauge is able to apply physical force with specialty payloads. By allowing sensors and tools to make contact with structures, Skygauge enables faster, safer, and more cost-effective inspections and maintenance for the world’s most critical infrastructure.
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