New aircraft sensors could warn pilots of dangerous ice build-up mid-flight

A new aircraft sensor system that can detect dangerous ice build-up in real time while continuing to provide critical flight data is being developed by University of Surrey start-up Surrey Sensors Limited in collaboration with Canada-based Flight Test Centre of Excellence dba Certification Center Canada.

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Airliner on an airport runway in a blizzard

Backed by funding from Innovate UK and the National Research Council of Canada, the project aims to deliver next-generation air data probe systems for aviation. These small devices sit on aircraft and measure the speed and direction of the airflow – both essential for safe flight – and can continue working reliably even in extreme conditions.

Ice build-up on aircraft is a known aviation hazard, capable of disrupting airflow, reducing lift and, in extreme cases, leading to loss of control. Existing airspeed measurement systems can struggle in these conditions, as ice, water or debris can block or damage the pressure sensors they rely on.

The new system combines two different technologies: the Airflow Performance Monitor (APM), developed by Certification Center Canada, which detects the effects of contamination such as ice on the aircraft’s surface, and Surrey Sensors’ waterproof micro-CTA sensors, which measure flow speed using heat transfer principles. Together, they provide real-time insight into how ice is affecting the aircraft’s performance – offering pilots earlier and more reliable warnings.

This technology is about giving aircraft a much clearer picture of what’s happening to their wings in real time. Combining different sensing approaches will help to make these measurements far more robust – particularly in the harsh conditions where current systems are most vulnerable. What’s important is not just detecting ice, but understanding how it is affecting the aircraft’s performance. That’s what allows for better, more reliable decisions in flight. Dr David Birch, Director of Research (Advanced Projects) at Surrey Sensors and Head of the University of Surrey’s Centre for Aerodynamics, Aerospace and Automotive Engineering

As well as improving safety, the technology could help reduce the need for energy-intensive anti-icing systems, which can significantly increase fuel consumption.

The system also has potential applications beyond fixed-wing aircraft. For example, there is currently no widely available technology that is able to measure airflow over helicopter rotor blades in real time – an issue which could be addressed with this technology.

Knowing your stall margin in all phases of flight is critical. Combining these technologies will both further address this safety issue and open up new possibilities for a rotary environment. Together, Surrey Sensors Limited and Flight Test Centre of Excellence are poised to set new standards in aerospace safety, efficiency and environmental sustainability through innovative airflow sensing technologies. Alistair Chapman, Director of Marketing at Certification Center Canada

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Notes to editors

Dr David Birch is available for interview; please contact mediarelations@surrey.ac.uk to arrange.

About Surrey Sensors Limited

Surrey Sensors Limited specialises in advanced miniature sensing technologies for aerospace, automotive, manufacturing and environmental applications. Learn more at www.surreysensors.com

About Certification Center Canada (3C)

Established by Marinvent Corporation, 3C is Canada’s only Transport Canada-approved Independent Flight Test and Certification Organisation. With extensive expertise in flight testing, certification and aerospace R&D, 3C is committed to advancing aerospace technology and safety standards. Learn more at www.certcentercanada.com

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Dr David Birch

Associate Professor of Aerospace Engineering; Head of Centre for Aerodynamics, Aerospace & Automotive Engineering

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