Scientists unveiled an upgraded FireDrone with aerogel insulation to survive 392 degrees Fahrenheit while flying inside burning buildings.
The Fire Drone is moving closer to real-world deployment after Swiss researchers unveiled a redesigned prototype equipped with an aerogel shell that allows it to operate inside burning buildings at 392 degrees Fahrenheit.
Developed at Empa and now refined by a spin-off of the Swiss Federal Institute of Technology in Lausanne , the new FireDrone builds on earlier prototypes by introducing a fundamentally redesigned protection system.Instead of the earlier multi-layer composite structure, the upgraded model boasts a one-piece insulation shell. Designed from high-temperature polyimide aerogel, the armor encases the drone’s sensitive parts in a single cast structure. This modification simplifies the drone’s thermal protection and internal insulation systems. Additionally, it boosts its durability and supports operation in high-risk environments with real-time monitoring.Inside the redesignFabian Wiesemüller, PhD, co-founder and CEO of FireDrone AG, said firefighters must physically enter burning buildings to spot hazardous materials or missing persons. “With the FireDrone, we can now send a drone into hazardous areas to do just that – significantly minimizing the risk during operations,” he said. Known for their exceptional thermal insulation, aerogels predominantly consist of air trapped within a porous solid matrix. The team noted it took them years to produce one that combines high heat resistance with mechanical flexibility. Their year-long efforts resulted in an ultra-light protective layer that shields the electronics while preserving maneuverability. Bringing both features together has long posed a challenge for scientists.The FireDrone is the first drone that can withstand extreme heat.Credit: EmpaConventional drones hit their limits at around 104 degrees Fahrenheit as their frame deforms and electronics fail. The new FireDrone in contrast, can fly at temperatures of up to 392 degrees Fahrenheit .“We can cast the aerogel in three-dimensional shapes and tailor it to the drone,” David Häusermann, MSc, CTO and co-founder of FireDrone, added. Apart from passive insulation, the upgraded drone now features active internal temperature management. It continuously cools and monitors onboard systems during flight. This hybrid approach allows it to remain operational in environments where toxic smoke, radiant heat, as well as unstable structures make human entry extremely dangerous.Flying into the flamesThe drone is equipped with an infrared camera. It transmits live thermal imagery to responders outside the danger zone. “Today, often only the first firefighters inside the building can see what it looks like inside,” Häusermann explained. “With the drone, the incident commander can get an overview of the situation before anyone enters the building,” he continued. At the same time, optional sensors can also be added to detect gases or measure external temperatures.The FireDrone is also built for indoor use. As it cannot rely on satellite navigation under these circumstances, it has been specifically optimized for use in buildings, tunnels, or covered industrial facilities. “GPS is not available in many of our operational scenarios,” Wiesemüller stated. “That’s why we are developing pilot assistance and localization systems that function reliably even without a satellite signal.”The drone will send data directly from danger zones.Credit: EmpaThe technology also shows promise in industrial inspection. It could examine cement and steel plants, or waste incineration facilities during operation, where the extreme heat limits human access and conventional drones. This could, in turn, significantly reduce downtime, costs and energy losses. The spin-off has already tested the FireDrone several times at the training ground of the Andelfingen training center and at the Holcim cement plant in Siggenthal. “Tests are crucial for making the transition from the laboratory to practical application,” Häusermann said in a press release. “In future, pilots should be able to use these drones safely in extreme situations with minimal training,” he concluded. In the long term, the drone will be paired with a mobile docking and maintenance station integrated into fire trucks or modern fire protection systems.
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