What is HALOSENSOR ® technology?

This technology was developed as an answer to the problem of accurately finding a pilot hole or feature through skin in aircraft structure assembly. It works through aluminium, carbon composite, titanium or any other non-ferrous materials but some grades of stainless steel can also be located using special targets. Finding the internal pilot hole from the outside skin gives accuracy advantages over traditional back drilling methods and eliminates the costly pipped hole or oval hole issues that have plagued the industry for many years. Our system is primarily used to locate datum hole positions for drill jigs or targets for robot vision systems to align virtual templates but some areas they are used to locate every hole. In repair maintenance or overhaul situations it is not possible to use the same sort of drill jigs from datum holes used in manufacture and every hole must be located, this system also gives time and scrap cost saving advantages compared to match drilling or other methods. We also supply push out type targets designed to be fixed into closed structure and pushed out by drill while being held captive using a lanyard.

Overview of HALOSENSOR® history

Patented technology invented in 1999 as a solution to back drill errors in discussions with BAE Systems, 1st prototypes to prove concepts in 1999 under NDA and patents filed in 2002.
HALOSENSOR ® technology is now used in production of every Airbus aircraft and by Boeing, Boeing Defense, Space & Security (BDS), Airbus Defence & Space, Bombardier, Embraer, BAE Systems, Lockheed Martin, Northrop Grumman, Leonardo, Dassault Aviation, COMAC, XAC, CAC, Spirit Aerostructures, Marshall Aerospace & Defence, Textron Aviation, Cessna, Bell Helicopter, Alenia Aermacchi, Hawker, GKN Aerostructures, JAXA, USAF, RAF, TAP Portugal, Turkish Technic, EADS-CASA, EADS-EFW, Premium Aerotech, Triumph Aerostructures, Marshall Aerospace & Defence, HAECO, Starco, GKN Aerostructures, Strata UAE and many more.


1999 Technology invented after discussions with BAE Systems as a solution to back drilling errors. Proof of concept prototype was designed and built by TT Electronics then evaluated by R&D engineers at BAE Systems.

2000 Stage 1 prototype for further capability testing in Filton

2002 Stage 2 prototype for production testing and approvals in Broughton, UK wing production.

2003 Approval for new production process and Airbus Single Aisle order for first 21 yellow V3 HEHS00001 production systems.

2004 Yellow system orders for long range / wide body and robotic sensor integration of ElectroImpact machines with new MINITSS7500001 robotic sensor. Development of long range calibrated targets.

2005 Introduction of the first V4 red systems HEHS8500001 and upgrade of Yellow V3 systems with V4 displays and connector to HEHS00003 model, Introduction of self-retaining push out targets.

2006 Introduction of the first V4 blue close to edge drilling unit HEHS00003CTE.

2007 Introduction of the first green PFD system designed to work with Luberring KL53 one shot drill & countersink machine HEHSTSSTEMP001.

2009 Development of the orange NANO system, small frame robotic inverted drilling system HEHSXYPFDxx and next generation robotic end effector sensor HEHSEIROBO001.

2010 Introduction of the first orange NANO HEHSTSSNANO001 production systems and sacrifice plastic pin targets.

2011 New modular PFD system HEHSTSSTEMPPFD001 developed to work with concentric collar clamped drill machines.

2012 Development of HEHSTSSTEMPPFD002 with hover-glide function for ease of use on top skin wing structures.

2013 – 2015 development of new robotic flex track systems HEHSMINIFTROBO001.

2015 Modification of HEHSTSSTEMPPFD002 to HEHSTSSTEMPPFD003 to include A350 PFD Bush and new sensor array.
2016 – 2017 Development of next generation battery box HEHSREDBAT3. Carbon dust & swarf extraction shuttle development for red HEHS8500001 system + A320 Step Change new process approval using single man operation and drill push out self-retained targets for single sided operation.

2017 – TT Electronics Technology Ltd was purchased along with AB Elektronik Sensor division from TT Electronics plc by AVX Corporation. We renamed to AVX Electronics Technology Ltd to reflect the change in ownership.

2018 – Development of next generation battery box HEHSREDBAT5 & display unit HEHSxxPDA2.

2021 – Management buyout of HALOSENSOR® technology by Global Business Manager and relocated to new premises in Essex UK. HALOSENSOR® products, brand, IP and manufacturing now under new company ZB3 Technologies Ltd. Developement of next generation integrated robotic drilling end effector sensor & ADU drilling systems.

With over 20 years’ experience solving customer’s Aerospace, Defence & Industrial production issues built on over 50 years sensor and engineering experience we are confident we can assist you with process changes to streamline your production.

Corresponance, Delivery, Shipping & Invoice address: ZB3 Technologies Ltd, Unit 30, 238 London Road, Wickford, Essex SS12 0JX, UK
Registered Office: ZB3 Technologies Ltd, Building 5b Beeches Road, Rawreth, Battlesbridge, Essex, SS11 8TJ, UK

HALOSENSOR ® is an international trademark of ZB3 Technologies Ltd & HALOSENSOR Electronics Technology Ltd.

For more information please contact info@zb3.uk.