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Why We Made the Elios 3
The first time I witnessed the Elios 3 in action was deep within the Kidd Mine in Timmins, Canada, which holds the title of the deepest operational underground mine in the world. I was there alongside UAS Inc., a leading company renowned for its expertise in conducting mining surveys using drones. Their reputation preceded them, and it was exciting to witness firsthand how this technology could revolutionize inspection processes.
As we descended 4,600 feet below the surface in the mining cage, we reached a gallery area suitable for our test flights. My colleague Johan Mlouka powered up the Elios 3, and almost immediately, the live 3D map on his tablet began painting a vivid picture of the surrounding environment. This level of situational awareness allowed him to navigate the drone with ease, relying heavily on the 3D model rather than direct visual contact with the drone itself.

This aspect of the Elios 3's operation was particularly striking. Unlike traditional drones that require constant line-of-sight control, the Elios 3 operates beyond visual line of sight (BVLOS), which is essential for accessing confined and potentially hazardous spaces. With the Elios 3, pilots can now rely on real-time 3D mapping to guide their flights, ensuring safe and efficient navigation even in the darkest corners of mines or other tight spaces.
That day at the Kidd Mine, the Elios 3 demonstrated its ability to create detailed 3D maps of stopes—massive excavated chambers—providing crucial insights into the structural integrity of the mine. Additionally, we tested its performance in extremely dusty environments, showcasing its resilience and adaptability.
The experience of piloting the Elios 3 was more than just a demonstration of advanced features; it felt like handling a tool that had evolved from being a technological marvel to becoming a reliable partner in industrial inspections. Much like how our smartphones have seamlessly integrated into daily life, offering convenience and functionality beyond just communication, the Elios 3 operates with such efficiency that it fades into the background, leaving operators free to focus solely on their tasks.
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### Three Key Takeaways
The development of the Elios 3 represents Flyability’s most ambitious project yet. Four years ago, we embarked on this journey by collaborating with top universities globally to explore the potential of robotic autonomy. Our efforts culminated in Team Cerberus winning DARPA’s prestigious Sub-T challenge, a testament to our commitment to advancing autonomous technologies in challenging subterranean environments.
However, the Elios 3 didn’t emerge from a lab—it was born in the field. Over 200 missions were conducted across diverse industrial settings, ensuring the drone met the rigorous demands of real-world applications. Through this extensive testing, we identified three critical insights that shaped the Elios 3’s design:
1. **Reliability Above All**: For inspectors, reliability is paramount. The Elios 3 ensures consistent performance through robust hardware and intelligent onboard systems, giving operators confidence in its capabilities.
2. **Ease of Use Drives Adoption**: While the Elios 2 showcased significant cost savings and safety improvements, scaling adoption required simplicity. The Elios 3 is designed to be intuitive, enabling new users to operate it effectively within minutes.
3. **Customization for Industry-Specific Needs**: From oil and gas to mining and utilities, each sector has unique inspection requirements. The Elios 3 is built as a modular platform, allowing for tailored hardware and software solutions to meet industry-specific needs.
If the Elios 2 resembles a classic flip phone, limited to basic functions, the Elios 3 is a smartphone—capable of running countless applications tailored to individual user needs. This versatility means the Elios 3 will continue evolving, with ongoing enhancements planned for both hardware and software to better serve our clients.
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### Deep Dive into the Elios 3’s Features
The Elios 3 stands out not only for its stability and ease of use but also for its innovative features. One standout component is FlyAware™, a proprietary SLAM engine housed within the drone’s body. FlyAware™ powers the Elios 3’s unparalleled stability, live 3D mapping, and reporting capabilities, laying the groundwork for future automation.
#### Stability
FlyAware™ processes input from multiple sensors—optical cameras and a LiDAR—to detect and counteract minute movements, ensuring the drone remains stationary in challenging conditions such as dust-filled or dark environments. This stability is crucial for collecting accurate data in environments where precision is non-negotiable.
#### Live 3D Mapping
Through the Cockpit app, pilots gain access to a live 3D map of the inspected area, significantly enhancing situational awareness. The LiDAR sensor acts as an indoor GPS, providing centimeter-accurate data that FlyAwareâ„¢ uses to construct real-time maps. This capability simplifies navigation and assessment of inspection coverage.
#### 3D Reporting
Inspector 4.0 complements the live mapping with 3D reporting tools. Pilots can tag points of interest (POIs) during flights, and upon docking, these POIs appear in a high-resolution 3D model. This contextualized data aids in planning repairs and aligning teams for execution.
#### Collision-Resilient Design
Equipped with a protective cage and reversing motors, the Elios 3 can recover from flips mid-flight without crashing, a unique advantage in confined spaces. Its rugged IP-44 design ensures durability against dust and water splashes.
#### Close-Up Inspection Payload
The Elios 3’s payload is optimized for close-up inspections, featuring a 4K camera, thermal imaging, and adjustable lighting. Its unobstructed 180° field of view ensures crystal-clear imagery, even in total darkness.
#### Modular Payload Bay
A modular payload bay supports dual payloads, currently housing the OS0-32 LiDAR sensor from Ouster. Future payload options are in development to cater to diverse industries.
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The Elios 3 isn’t just a drone; it’s a transformative tool for professionals needing to gather data in confined spaces. Join us at our upcoming demo days worldwide to experience its potential firsthand.