Contact Energy and Syos Aerospace – Underwater Robotic Coating Measurement and Inspection System

Syos Aerospace developed and successfully deployed a world-first underwater robotic inspection system for live coating thickness measurement of submerged hydroelectric penstocks in New Zealand. The system combined advanced ROV technology, robotic manipulation, ultrasonic sensing, and custom dual-spring probe engineering to achieve highly repeatable micron-level measurements underwater without dewatering the assets. The innovation reduced inspection 
downtime from 3–4 days per penstock to approximately three hours while improving inspection coverage and operational efficiency. Successfully deployed on critical hydroelectric infrastructure, the project demonstrated a globally unique robotic inspection capability developed and fielded by a small New Zealand engineering team.