Proof-of-concept case study: Corridor-scale BVLOS utility inspection using lidar and RGB intelligence

On May 12–13, 2026, Censys Technologies conducted a multi-location Beyond Visual Line of Sight (BVLOS) proof-of-concept operation for a regional electric utility across transmission, distribution, and service-line infrastructure in central Ohio. The mission was designed to evaluate the operational feasibility of long-range corridor mapping using the Sentaero 6 unmanned aircraft system equipped with TV540 LiDAR and RGB payload technology. Over the course of six separate flights, the operation logged 158 total flight miles. The mission combined LiDAR and RGB data collection into a single operational workflow, allowing the team to capture measurable infrastructure and vegetation intelligence simultaneously. The proof-of-concept was executed under real-world operational constraints, including compressed planning timelines, shifting launch and recovery locations, deviations from system KML’s to real-world locations, changing environmental conditions, and complex field logistics. Despite these challenges, the operation demonstrated how system-wide aerial intelligence can support scalable utility inspection and vegetation analysis workflows using fixed-wing BVLOS systems today. Following collection, a one-mile dataset was processed through the CensWise platform, where vegetation encroachment analysis identified 54 detections through automated processing and manual review workflows. These mission deliverables required RAW data, and the one-mile dataset was used to highlight and demonstrate capabilities This document outlines three distinct operational models designed to help mitigate Customer Minutes Interrupted (CMI), each with its own cost structure and level of internal commitment required from the utility. The analysis and workflows behind these models are built around the realities of operating and inspecting an approximately 35,000-mile powerline network at infrastructure scale. MISSION OBJECTIVE The primary objective of the mission was to conduct corridor mapping operations using the TV540 LiDAR and RGB payload system integrated into the Sentaero 6 platform. Secondary objectives focused on demonstrating operational capability and validating workflows as part of a proof-of-concept engagement with the utility. The operation targeted multiple forms of electrical infrastructure, including: - Utility transmission lines - Distribution infrastructure - Service-line environments Initial mission goals targeted approximately 125 corridor miles. Across the two-day operation, the team exceeded those expectations by flying 158 total miles across six operational sorties. Equipment Utilized: The mission was flown using the Sentaero 6 fixed-wing VTOL unmanned aircraft system. The aircraft was configured with the TV540 LiDAR and 45 MP RGB imaging payload, enabling simultaneous collection of: - LiDAR point cloud data - High-resolution RGB imagery This integrated payload configuration allowed the crew to capture measurable spatial intelligence and visual verification data within a single flight operation. The combined LiDAR and RGB workflow supports: - Vegetation encroachment analysis - Infrastructure modeling - Corridor mapping - Asset visibility and contextual verification By combining long-endurance BVLOS capability with simultaneous multi-modal data capture, the operation demonstrated how utilities can reduce fragmented collection workflows while increasing inspection efficiency across large geographic areas. Mission Planning and Site Preparation The operation required approximately 27 hours of combined planning and preparation prior to flight execution. Planning activities included the following: Mission preparation involved both digital and physical corridor assessments and in-field route validation. The crew identified several operational hazards and constraints, including: - Radio towers - Water towers - Elevation changes - Limited corridor accessibility - Inaccurate utility KML datasets One of the largest operational challenges involved launch and recovery site (LRS) selection. Many originally planned locations proved inaccessible upon arrival, forcing crews to identify alternative launch locations dynamically while simultaneously conducting field operations. Several sorties were ultimately launched from improvised staging locations, including church parking lots and public access areas. Operational Environment and Risk Mitigation The operation was conducted within Class E and G airspace under FAA-approved shielded operations. Flight operations were conducted at approximately 200 feet above utility structures and obstacles along the flight path. Risk mitigation procedures included: - Geofencing around radio towers - Avoidance of densely populated areas - Flight path adjustments around ground structures - Filing NOTAMs for three operational areas - Ground-risk review of roadway crossings and corridor exposure areas The crew also coordinated directly with the utility’s aviation team to identify viable launch and recovery sites throughout the operation. Environmental conditions introduced additional operational complexity. High winds and rain were forecasted during the mission window, though they ultimately did not prevent flight operations. Low-flying helicopter activity caused delays during one sortie and required operational pauses while maintaining airspace awareness. FLIGHT EXECUTION The proof-of-concept consisted of six flight operations conducted across multiple geographic locations in the utility’s central Ohio service territory. Operations began on May 12 with initial corridor mapping flights launched from the first staging location before expanding into multiple distributed launch locations throughout the operating area. As flight operations progressed, crews dynamically adjusted launch and recovery sites to accommodate accessibility constraints and evolving corridor requirements. The operation concluded on May 13 following the sixth sortie. Total operational distance reached 158 combined flight miles across the two-day operation. Operational crews included two Censys Technologies flight personnel and two utility personnel coordinating ground support and airspace operations. Operational Observations and Execution Challenges The mission highlighted several operational realities associated with scaling long-range BVLOS utility inspection programs under evolving field conditions. Key operational observations included: - Dynamic launch site adjustments in the field - Real-time mission replanning requirements - Support equipment affecting data handling efficiency - Complex corridor validation requirements - Environmental and airspace coordination considerations Launch and recovery site selection proved to be one of the most significant operational challenges throughout the proof-of-concept. Many originally planned staging areas were inaccessible upon arrival, requiring crews to identify alternative launch locations in real-time while maintaining mission timelines and corridor objectives. Several sorties were ultimately launched from improvised field locations, including public access and church parking areas. The mission also reinforced the importance of: - Accurate utility corridor datasets - Thorough site validation - Flexible mission planning workflows - Operational adaptability in the field - Coordinated planning between the utility and flight teams The mission required crews to conduct site surveys, validate corridor routes, identify alternative launch locations, and execute flight operations simultaneously in real time under field conditions. These operational realities highlighted the importance of disciplined planning, standardized workflows, and operational readiness when scaling corridor-based BVLOS inspection programs. These operational insights are critical for organizations preparing to scale repeatable corridor-based BVLOS inspection programs across large utility networks. Data Ingestion and Analysis The mission collected 220GB of total raw data. This mission leveraged both RGB imagery and LiDAR; however, two flights occurred during dusk, limiting the effectiveness of RGB collection. Despite the reduced daylight, LiDAR continued to deliver high-quality, actionable data across the entire corridor. Data processing workflows moved through multiple ingestion and conversion stages before entering the CensWise analysis environment. Processing timelines for one mile of classified data totaled approximately 5 minutes. Analysis workflows identified 54 vegetation encroachment detections through automated processing and manual review validation. The operation also surfaced several workflow insights around utility corridor modeling, including the importance of accurate centerline mapping and handling non-linear corridor datasets with multiple branching powerline structures. Why This Mission Matters For the utility, where approximately one-third of outages are vegetation-related, scalable corridor intelligence and repeatable inspection workflows become increasingly important for reducing operational risk and mitigating Customer Minutes Interrupted (CMI). The operation showed that fixed-wing drone systems equipped with integrated LiDAR and RGB payloads can: - Capture measurable infrastructure intelligence at scale - Support vegetation analysis workflows - Cover large utility networks efficiently - Operate across distributed launch environments - Deliver actionable aerial intelligence for utility stakeholders Equally important, the mission reinforced that scalable BVLOS operations require more than aircraft capability alone. They require: - Strong operational planning (eventual automation of it) - Accurate corridor intelligence - Coordinated field execution or networked robotics - Flexible deployment workflows - Repeatable operational discipline - Real-world adaptability The proof-of-concept provided the utility and Censys Technologies with practical operational insight into how long-range aerial intelligence can support future utility inspection and vegetation management workflows at system-wide scale. Long-range BVLOS operations are not simply about flying farther. They are about building operational systems capable of delivering repeatable, measurable intelligence across real infrastructure environments. COST ANALYSIS To understand the operational economics of the proof-of-concept mission, a fully loaded cost model was developed based on the personnel, equipment, and support assets required to execute corridor-scale UAS operations. Because vegetation-related events account for approximately one-third of outages within the utility’s network, reducing inspection cycle times and increasing corridor visibility can have a direct impact on reliability performance and outage mitigation. The model includes two full-time operational crews, the Sentaero 6 aircraft, the TV540 payload, supporting hardware, software licensing, and the mission support vehicle. Capital equipment costs were amortized over their expected service life to represent the annual operational burden of the system. Operational production assumptions were derived from the actual mission profile and scaled across a typical operational year. From these inputs, the following operational cost metrics were calculated. These results illustrate the economics of long-range corridor inspections, where a single aircraft can collect data across tens of miles of infrastructure during a single mission. These values represent the fully loaded cost of operating the Censys system, accounting for personnel, aircraft, payload, and supporting infrastructure. In practical terms, they provide a realistic expectation of the cost structure organizations can anticipate when deploying this operational model. This mission required approximately 27 hours of planning and preparation, including mission design, regulatory coordination, and operational setup. These activities represent initial program development and are not required for every flight. Once a corridor mission has been established, repeat operations can be executed far more efficiently. The following section illustrates how this operational model scales over time. Final Cost & Value Comparison Model A — Human in Field (Truck + Pilot + Mobile Command Center) CapEx (Utility-owned): - 7 × Sentaero 6: $140,000 each - 7 × TV540 LiDAR: $80,000 each - 7 × Mobile Command Center: $160,000 - 14 FTEs required just for data collection Total CapEx: $2,660,000 (Mobile Command Center pricing is consistent with internal quote benchmarks for trailer-based mobile command systems) Model B — EdgeDock Network (12 Nodes; Edge Enabled) CapEx (Utility-owned): - 12 × EdgeDock: $304,000 each - 6 × Sentaero 6E: $180,000 each - 6 × TV540 LiDAR: $80,000 each - 6 × Raptors: $60,000 each - 2 FTEs to operate the network, plus consume deliverables - + Ancillary required equipment and services: Total CapEx: $6,710,148 Model C — DaaS EdgeDock Network (12 Nodes; Edge Enabled) CapEx (Censys-owned): - $0 CapEx’ed Hardware - $200/mile/year in CapEx digital twin: $7M per year plus internal labor to consume deliverables.