Precision Instrumentation for Uncrewed Aircraft Systems
Custom thermocouples, RTDs, wire harnesses, and Aerosensor aerodynamic measurement probes — engineered for the weight, space, and accuracy demands of UAS development and flight test.
Lightweight, Compact Instrumentation for Uncrewed Platforms
UAS development places unusual demands on instrumentation: every gram and every millimeter affects flight performance, and sensors must hold calibration through vibration, temperature swings, and repeated flight cycles. K-Tec Systems manufactures custom thermocouples, RTDs, and wire harnesses in-house, and serves as the authorized U.S. distributor for Aerosensor precision aerodynamic probes — giving UAS engineering teams a single, qualified source for temperature, pressure, and flow measurement.
Aerosensor’s compact multi-hole probes, Kiel probes, and yaw pitots are manufactured down to a 1.6mm minimum diameter using Direct Metal Laser Sintering (DMLS), with titanium available for weight-critical builds. Paired with K-Tec’s custom wire harnesses and temperature sensors, the result is a flight-ready instrumentation package built to your platform’s exact constraints.
Where K-Tec Instrumentation Supports UAS Programs
From bench-level propulsion testing to in-flight aerodynamic data acquisition, K-Tec’s instrumentation is sized and engineered for uncrewed aircraft constraints.
Air Data Sensing for Flight Control
Compact Aerosensor probes for airspeed, angle of attack, and yaw measurement feeding flight control and air data systems. Minimum diameters as small as 1.6mm suit small and medium airframes without compromising aerodynamics.
Propulsion & Powertrain Testing
Custom thermocouples and RTDs for motor, battery, and engine temperature monitoring on electric, hybrid, and small turbine UAS propulsion systems. Inconel-sheathed probes available for high-temperature zones up to 980°C.
Flight Test Instrumentation
Lightweight, low-drag probe configurations for in-flight aerodynamic data acquisition. Yaw pitots for simultaneous dynamic pressure and yaw angle measurement, supporting flight test correlation with wind tunnel and CFD data.
Airframe & Nose-Mounted Sensing
Multi-hole probes with optional integrated static ring for accurate static pressure measurement on UAV noses, where low-pressure-gradient conditions require additional precision.
Wind Tunnel Development Testing
Kiel probes, multi-hole probes, and Kiel rakes for total pressure, static pressure, and three-dimensional flow vector measurement during UAS aerodynamic development. Individually calibrated probes with lookup tables ready for real-time or post-processing workflows.
Custom Wiring & Sensor Integration
Custom wire harness assemblies built to your routing and weight requirements, integrating sensor leads throughout the airframe — built for reliable signal integrity under vibration and repeated flight cycles.
Instrumentation Built for UAS Constraints
Custom temperature sensors and wiring manufactured in-house, paired with Aerosensor’s compact aerodynamic probe line — sized, weighted, and rated for uncrewed platforms.
Custom Thermocouples
Built to your exact specification for motor, battery, and powertrain temperature monitoring. Inconel sheathing available for high-temperature zones up to 980°C.
- TypesJ, K, T, E & more
- InsulationMgO (standard)
- CalibrationNIST traceable
- DocumentationCertificate of Conformance
RTDs (Resistance Temperature Detectors)
Higher accuracy and repeatability than thermocouples at moderate temperatures — well suited to battery and avionics bay temperature monitoring on UAS platforms.
- ElementPt100, Pt1000
- ClassA or B per IEC 60751
- CalibrationNIST traceable
- DocumentationCertificate of Conformance
Wire Harnesses
Custom wire harness assemblies built to your routing and weight requirements. Used for sensor integration throughout the airframe, where reliable signal integrity under vibration and temperature cycling is essential.
- BuildCustom to your specs
- EnvironmentHigh vibration, temp cycling
- DocumentationCertificate of Conformance
Yaw Pitots
Simultaneous dynamic pressure and yaw angle measurement in a single instrument. Supports flight test correlation with wind tunnel and CFD data on UAS development programs.
- Accuracy±0.25%
- Yaw rangeUp to ±30°
- Max temp980°C
Kiel Probes
Total pressure measurement across wide flow angles in a compact, lightweight package. Extends reliable measurement to ±50° — far beyond the ±5° limitation of a standard pitot tube.
- Accuracy±0.1%
- Flow anglesUp to ±50°
- Max temp980°C
- Min dia.1.6mm
5-Hole Probes
Full 3D flow vector resolution — total pressure, static pressure, yaw, and pitch — from a single probe position. Down to 2mm head diameter, suited to nose-mounted installation on small airframes.
- Accuracy±0.25%
- Flow anglesUp to ±45°
- Max temp980°C
- Min dia.2mm
Kiel Rakes
Multi-point total pressure measurement across a defined area simultaneously. Monolithic DMLS or modular machined assemblies, configurable to fit constrained UAS airframe geometries.
- ConstructionDMLS or machined
- MaterialSS, Inconel, titanium
- ConfigCustom geometry
Integrated Temperature and Aerodynamic Measurement
K-Tec’s custom thermocouple wire can be incorporated directly into Aerosensor probe assemblies for simultaneous flow and temperature measurement from a single instrument. Wire type and integration method are specified to your exact platform requirements — delivered as a complete, documented solution from a single supplier.
Built for UAS Program Procurement Requirements
K-Tec thermocouples are produced to ISO/IEC 17025 standards — the internationally recognized standard for testing and calibration laboratories. This is a critical qualification for aerospace and defense-adjacent procurement.
All calibration equipment maintains full traceability to the National Institute of Standards and Technology. A Certificate of Conformance is provided with every thermocouple and RTD order.
All thermocouples are manufactured in compliance with ANSI/ASTM thermocouple standards, ensuring accuracy, consistency, and interchangeability across your test instrumentation.
K-Tec Systems is registered to do business with the U.S. Government. CAGE Code: 4W0S0. SBA Small Business. Accepts U.S. Government purchase cards.
K-Tec Systems is a certified woman-owned business, recognized by the Women’s Business Enterprise National Council (WBENC) and certified as a Women-Owned Small Business (WOSB).
Every Aerosensor probe is individually calibrated in an in-house wind tunnel across five discrete flow speeds and the full operating yaw and pitch angle range. Calibration data is supplied as lookup tables.
What Sets Us Apart for UAS Programs
Custom thermocouples, RTDs, wire harnesses, and Aerosensor precision probes — all available through a single qualified supplier. Fewer vendors, consolidated documentation, single point of contact.
Aerosensor probes down to 1.6mm minimum diameter, with titanium construction available where every gram matters. Custom wire harnesses built to your routing and weight requirements.
Every thermocouple, RTD, and harness is built to your specifications. Aerosensor probes are available in custom geometries, materials, and configurations. No standard-part compromises on critical measurement points.
Certificate of Conformance with every order. NIST traceable calibration. Aerosensor calibration data supplied as lookup tables ready for integration into test software.
MgO-insulated thermocouples for high-vibration environments. Aerosensor probes in Inconel rated to 980°C. Titanium available for weight-critical applications.
Thermocouples, RTDs, and wire harnesses manufactured in Ferndale, Michigan. Direct engineering support from specification through delivery. CAGE Code 4W0S0 — qualified for U.S. Government procurement.
Talk to Our Engineering Team
Describe your platform and measurement requirements. Our team will identify the right sensors, probes, and configurations — and can provide documentation to support your procurement process.
Request a Quote