Advanced Fail-Safe Pilot Covers That Will Save Lives and Money

Photo Credits: The Aviator Store

Pilot tube covers have remained largely unchanged for the better part of the last century, typically existing as simple covers, some with red “remove before flight” streamers that rely on human attention. American aviation company DeGroff Technologies aims to eliminate the risk posed when one is accidentally left on during a flight. 

Steven DeGroff, President of DeGroff Technologies, said that there will always be a possibility of human error in operations, so technology must be designed to prevent hazards within the system itself. 

Traditional covers can lead to costly replacements and safety risks, as they may melt or damage heated pitot tubes if the heat is activated while the covers are still attached. 

“You may have three or four ruined pitot tubes… and you may have hundreds of thousands of dollars in costs, in time, and in materials,” said DeGroff, depending on the aircraft type. 

Beyond the financial implications, traditional covers have also been linked to serious incidents. In one case involving a Bombardier Challenger 300 in Connecticut, pitot covers left on the aircraft contributed to a rejected takeoff. When the sensors were not properly reset before departure, in-flight oscillations occurred, resulting in injuries and the eventual death of a passenger. 

The technology developed by DeGroff integrates a small glass bulb—like those used in fire sprinkler systems—inside a clamshell-style pitot cover. Within two to five minutes of the engine starting, the bulb heats up, expands, and shatters. This results in the cover opening, freeing the pitot tube before any damage can occur. This mechanism and its implementation can save lives and cut costs simultaneously.