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Case 04 · Aria · Solar Farm Survey · Shipped 2025
// Case 04 · 2025 · Aerial Survey · Autonomy

Ariasolar survey.

An autonomous photogrammetry pipeline for utility-scale solar farms. PX4 + custom mission planner, gimbal-stabilised RGB+thermal capture, RTK-pinned waypoints — 240ha surveyed in 41 minutes.

EngagementFixed-price
StackPX4 · ROS 2
Timeline14 weeks
StatusIn production
aria.internal/mission
Aria — mission planner and live flight view
Chapter 01 · The Brief

240 hectares.
A full day's work. Per crew.

Utility-scale solar operators were flying manual drone surveys with consumer hardware — one pilot, one battery swap per 20ha, no RTK correction, no thermal layer. A site inspection took a full crew day per 240ha block. Mosaics came back misaligned; hot-spot detection required a second pass.

The brief: a fully autonomous pipeline — plan a mission once, fly it repeatably, capture RTK-accurate RGB and thermal simultaneously, stitch georeferenced orthomosaics on-site, and surface anomalies before the crew packs up.

Brief at a glance
Client
Utility-scale solar operator, California
Site
240ha · 3 MW installation
Problem
Manual surveys: 1 day · no thermal layer · misaligned mosaics
Goal
Autonomous RGB+thermal survey in under 2 hours
Constraint
FAA Part 107 · BVLOS waiver required
Chapter 02 · The Approach

Mission planned
once. Flown forever.

Autonomous Mission Stack

We built a custom mission planner on top of PX4 + MAVSDK that ingests a KML site boundary, auto-generates a lawnmower grid at configurable altitude and overlap, calculates wind-adjusted waypoints, and uploads to the flight controller. RTK correction from a base station gives 2.3cm horizontal accuracy — no GCPs required.

The gimbal carries a dual-sensor payload: 20MP RGB for photogrammetry and a radiometric thermal camera for hot-spot detection. Both fire on the same trigger signal so every frame is spatially co-registered.

On-Site Processing

A ruggedised edge box running ROS 2 + OpenDroneMap processes imagery during the flight — by the time the drone lands, a georeferenced orthomosaic is ready. A Python post-processor runs anomaly detection on the thermal layer and overlays flagged panels on the RGB mosaic.

The operator sees a heatmap of suspect panels on a web dashboard before they've packed the ground station. No cloud upload required; everything runs on-site.

Chapter 04 · By the numbers
240ha
Surveyed
per flight.
vs ~20ha manual
12×
Faster than
a ground crew.
41 min vs 8h
2.3cm
RTK horizontal
accuracy.
no GCPs needed
0
Manual
stitching steps.
fully automated
Chapter 05 · Inside the mission

Plan it, fly it,
read the result.

Mission planner, live telemetry, orthomosaic viewer, and thermal anomaly overlay — the full survey pipeline in one tool.

// 01 · Plan
Aria — mission planner with waypoint grid

KML boundary → auto-generated lawnmower grid with RTK waypoints.

// 02 · Fly
Aria — live flight telemetry dashboard

Live position, altitude, battery, and gimbal status mid-flight.

// 03 · Mosaic
Aria — RGB orthomosaic output

Georeferenced orthomosaic stitched on-site before landing.

// 04 · Thermal
Aria — thermal anomaly heatmap overlay

Suspect panels flagged on the thermal layer before pack-up.

// 05 · Report
Aria — anomaly report export

Panel coordinates and severity scores exported for maintenance.

click to expand · drag to explore
Closing

The
credits.

  • Engagement
    Fixed-price · 14-week program
  • Airframe
    Custom hex · 8kg MTOW · dual-battery
  • Flight Stack
    PX4 · MAVSDK · custom mission planner
  • Comms
    MAVLink · RTCM RTK correction · 900 MHz telemetry
  • Payload
    20MP RGB · radiometric thermal · stabilised gimbal
  • Processing
    ROS 2 · OpenDroneMap · Python anomaly detection
  • Dashboard
    Next.js · WebSocket telemetry · Mapbox GL
  • Compliance
    FAA Part 107 · BVLOS waiver · site safety plan
  • Status
    In production · 4 sites · quarterly survey schedule