Innovators of HALOSENSOR® Through Skin Sensor Technology

ZB3 Technologies Ltd stands at the forefront of aerospace smart tooling technology. Since 2003, we’ve been revolutionizing the global aero structures market with our unique patented HALOSENSOR® technology. Our mission is to provide solutions that enhance all stages of the aero manufacturing and MRO processes.

Our Expertise

At ZB3 Technologies Ltd, we specialize in manual, semi-robotic, and robotic drill position sensors, as well as smart tooling solutions. We are proud to serve a prestigious list of clients that includes industry giants such as Airbus, Boeing, Bombardier, Embraer, Spirit AeroSystems, Dassault Aviation, BAE Systems, Lockheed Martin, Northrop Grumman, and many more.

Custom Solutions for Aerospace Challenges

While we offer a range of standard manual and robotic drill position targeting systems suitable for most airframe manufacturing requirements, our true expertise shines when developing custom solutions. When faced with repeated drill issues, repair access challenges, or the development of new airframe production processes, we step in to save you time and money with HALOSENSOR® technologies.

HALOSENSOR® Technology Unleashed

Our patented HALOSENSOR® technology is a groundbreaking solution born out of discussions with BAE Systems in 1999. It was designed to tackle the persistent problem of accurately locating blind pilot holes or features through skin in aircraft structure assembly. This technology boasts the capability to work through various materials, including aluminium, carbon composites, titanium, and non-ferrous materials. Special targets even enable the detection of certain grades of stainless steel.

HALOSENSOR® technology offers unmatched accuracy advantages over traditional back drilling or match drilling methods. It eliminates costly issues like pipped holes and oval holes that have long plagued the aerospace industry. Our system excels at locating datum hole positions for drill jigs and aligning virtual templates in robot vision systems. Moreover, it plays a pivotal role in repairing, maintaining, and overhauling aircraft by accurately locating every hole in skin replacements.

The HALOSENSOR® Journey

Our journey with HALOSENSOR® technology began with the invention of prototypes in 1999, followed by patent filings in 2002. Today, HALOSENSOR® technology is integral to the production of Airbus and Boeing aircraft, as well as many other renowned aerospace companies and organizations.

Company Timeline

  • 1999: Invention of HALOSENSOR® technology as a solution to BAE Systems’ structural production issues.
    • Conceptualized technology to address back drilling errors.
  • 2000: Stage 1 Prototype Development
    • Designed and built proof of concept prototype by TT Electronics, evaluated by R&D engineers at BAE Systems.
  • 2002: Stage 2 Prototype for Production Testing
    • Developed prototypes for production testing and approvals.
  • 2003: Industry Approval and First Airbus Order
    • Gained approval for new production processes.
    • Received the first order from Airbus Single Aisle.
  • 2004: Expansion into Yellow System and Robotic Integration
    • Yellow system orders for long-range/wide-body applications.
    • Integration of robotic sensors with ElectroImpact machines.
    • Development of long-range calibrated targets.
  • 2005: Introduction of V4 Red Systems and Upgrades
    • Introduced V4 red systems (HEHS8500001).
    • Upgraded Yellow V3 systems with V4 displays.
    • Introduction of self-retaining push-out targets.
  • 2006: Debut of V4 Blue Close-to-Edge Drilling Unit
    • Introduced the first V4 blue close-to-edge drilling unit (HEHS00003CTE).
  • 2007: Introduction of Green PFD System
    • Launched the first green PFD system designed to work with Luberring KL53 one-shot drill & countersink machine (HEHSTSSTEMP001).
  • 2009: Development of Orange NANO System
    • Developed the orange NANO system, designed for small frame robotic inverted drilling.
  • 2010: Introduction of Orange NANO Production Systems
    • Introduced the first orange NANO production systems (HEHSTSSNANO001).
    • Sacrifice plastic pin targets were introduced.
  • 2011: Modular PFD System Development
    • Developed the new modular PFD system (HEHSTSSTEMPPFD001) designed to work with concentric collar-clamped drill machines.
  • 2012: Enhanced Hover-Glide Functionality
    • Enhanced HEHSTSSTEMPPFD002 with hover-glide function for ease of use on top skin wing structures.
  • 2013 – 2015: Development of Robotic Flex Track Systems
    • Developed new robotic flex track systems (HEHSMINIFTROBO001).
  • 2015: Modification and Expansion
    • Modified HEHSTSSTEMPPFD002 to HEHSTSSTEMPPFD003 to include A350 PFD Bush and new sensor array.
  • 2016 – 2017: Next-Generation Battery Box and Process Improvements
    • Developed next-generation battery box HEHSREDBAT3.
    • Developed carbon dust & swarf extraction shuttle for red HEHS8500001 system.
    • A320 Step Change new process approval with single-man operation and drill push-out self-retained targets for single-sided operation.
  • 2017: Ownership Transition
    • TT Electronics Technology Ltd was acquired by AVX Corporation along with AB Elektronik Sensor division.
    • Renamed to AVX Electronics Technology Ltd to reflect the change in ownership.
  • 2018: Next-Generation Battery Box and Display Unit
    • Developed next-generation battery box HEHSREDBAT5.
    • Introduced display unit HEHSxxPDA2.
  • 2021: Management Buyout and Relocation
    • Management buyout of HALOSENSOR® technology by Global Business Manager.
    • Relocated to new premises in Essex, UK, under ZB3 Technologies Ltd.
    • Development of next generation nosepiece integrated robotic drilling end effector sensor & ADU drilling systems.

Get in Touch

With over two decades of experience solving production issues in Aerospace, Defence, and Industrial sectors, we are ready to assist you in streamlining your production processes.

For technical information and sales please contact: sales@zb3.uk

Contact Us

Correspondence, Delivery, Shipping & Invoice Address: ZB3 Technologies Ltd, Unit 30, 238 London Road Wickford, Essex SS12 0JX, UK

Registered Office: ZB3 Technologies Ltd, The Mousery, Beeches Road, Wickford, Essex, SS11 8GH, UK

HALOSENSOR® is an international trademark of ZB3 Technologies Ltd

For more information, please contact info@zb3.uk