The accuracy, robustness and affordability of localisation are fundamental to autonomous robotic inspection within aircraft maintenance, repair and overhaul (MRO) hangars. Hangars typically have high ceilings and are predominantly steel-framed structures with metal cladding. Because of this, they are regarded as GPS-denied environments, characterised by significant multipath effects and strict operational constraints, which together form a unique challenging setting. The lack of comparative techno-economic benchmarks for localisation technologies in such environments remains a critical gap. Addressing this, the paper presents the first techno-economic analysis that benchmarks motion capture (MoCap), ultra-wideband (UWB) and a ceiling-mounted camera (CMC) system across three operational scenarios: robot localisation, asset monitoring and surface defect detection within a single-bay hangar. A two-stage optimisation framework for camera selection and placement is introduced, which couples market-based camera-lens selection with an optimisation solver, producing camera layouts that minimise hardware while meeting accuracy and coverage targets. The consolidated blueprints provide quantification of the required equipment and its performance: 15 global-shutter GigE cameras are adequate for drone localisation, 9 cameras meet the requirements for on-bay monitoring and 49 high-resolution cameras facilitate defect mapping of the upper airframe surfaces for midsize defects. Across these scenarios, the study reports indicative performance and cost envelopes: a MoCap installation delivers submillimeter localisation at an estimated £190k per bay, UWB delivers centimetre-level tracking for around £49k and the proposed CMC system layouts achieve task-specific coverage with costs in the £9k–£77k range. The analysis equips MRO planners with an actionable method to balance accuracy, coverage and budget, demonstrating that an optimised CMC system can deliver robust and cost-effective sensing for next-generation smart hangars.

Aircraft maintenance is a multifaceted process that requires highly skilled, qualified and experienced personnel. Effective maintenance processes optimise aircraft operational lifespan, minimise lifecycle costs and improve reliability by reducing the probability of unexpected maintenance events. The initial diagnostic phase relies on detailed visual inspections conducted by certified technicians. Following inspections, data assessment leads to the development of a comprehensive maintenance plan, along with the sourcing of necessary resources and spare parts. As the maintenance, repair and overhaul (MRO) sector transitions into the era of Industry 4.0, there is a growing emphasis on integrating data analytics and cyber-physical systems into maintenance practices. A key objective in this evolution is the adoption of robotic systems for inspection tasks. This shift requires the reconfiguration of formal inspection procedures to ensure compatibility with robotic operations. Moreover, it is critical to address the specific requirements of robotics and to incorporate smart hangar technologies that take advantage of real-time data to improve both efficiency and effectiveness in maintenance operations. This study provides a comprehensive review of the MRO landscape and maintenance checks, with a particular focus on robotic aircraft inspection systems, navigation and smart hangar infrastructure. The discussion concludes with an examination of defect detection methods using machine vision along with relevant metrics to compare with human performance.

Sustainability is becoming a major strategic driver within the aviation industry, which has moved from providing primarily economic benefits to delivering the ‘triple bottom line’, including social and environmental impact as well as financial performance. Sustainable aviation is also being tracked by the International Civil Aviation Organisation (ICAO) Global Collation for Sustainable Aviation. Operations and Infrastructure is an important near-term opportunity to deliver sustainability benefits. Digital Technologies, Integrated Vehicle Health Management (IVHM) and Maintenance Repair and Overhaul (MRO) play a prominent role in implementing these benefits, with a particular focus on operational efficiencies. As part of this, the sustainable smart hangar of the future is a concept that is becoming more and more important in forming the future of the aviation industry. The Hangar of the Future is an excellent opportunity for innovation, combining the progress in manufacturing, materials, robotics and artificial intelligence technologies. Succeeding in developing a hangar with these characteristics will provide us with potential benefits ranging from reduced downtime and costs to improved safety and environmental impact. This work explores some of the key features related to the sustainable smart hangar of the future by discussing research that takes place in DARTeC’s (Digital Aviation Research and Technology Centre) hangar led by the IVHM Centre in Cranfield. Additionally, the paper touches on some longer-term aspirations.

Composite materials are enjoying an increasing use in aircraft structures. As more fleets transition from metal to more composite aircraft, the practice of maintenance is also adjusting. Handling, inspection and repair of aircraft composites following non-visible or barely visible damage are among the areas of concern, due to associated cost and safety implications. A pilot study was performed to explore the level of awareness and understanding of aviation maintenance practitioners around these issues. In addition, this research project sought to identify factors related to the technical/engineering judgement capacity of the personnel working with composites and to gauge the need for specialised education and training. A questionnaire survey was administered to a group of 40 professionals working for an aircraft maintenance, repair and overhaul (MRO) organisation. Descriptive statistics in conjunction with analysis of variance (ANOVA) were used to analyse the results. The sources of impact and common areas affected on the aircraft have been identified, with situational awareness suggested as the most important mitigator against impact damage. Over 70% of the participants would refer to their engineering manager for instructions on how to handle composite damage. The need for higher standardisation for composites’ maintenance, repair and handling issues emerged as a common theme across different sections of the survey. Almost all respondents agree on the need for specialised knowledge and training for the handling, repair and inspection of composites.