US Navy Deploys Gecko Robotics for Advanced Ship Hull Inspections
AI-powered wall-crawling robots accelerate structural maintenance while significantly reducing naval repair costs.
1Naval Maintenance Challenges
The USS Abraham Lincoln returned to port in August 2026 showing significant rust accumulation. Saltwater corrosion frequently causes structural cracks in hulls, creating persistent maintenance burdens for the United States Navy. Identifying these defects manually is a slow, labor-intensive process that historically required scraping paint from random hull spots to assess integrity.
2Strategic Partnership Details
In October 2026, the Navy finalized a $300 million contract with Gecko Robotics to integrate artificial intelligence into ship inspections. This initiative aims to streamline repair workflows significantly. By utilizing advanced robotic systems, the Navy expects to save up to $8 million per vessel while accelerating inspection timelines from months to days.
3Komodo System Capabilities
Gecko Robotics utilizes the Komodo machine system, which physically climbs ship walls to gather diagnostic data. These drones employ sophisticated sensors to analyze deck coatings and hull integrity without requiring invasive physical digging. This automated approach allows for comprehensive scanning of entire hull plates, including critical frames and seams, during drydock operations.
4EMAT Sensor Technology
The core of this inspection technology is the Electromagnetic Acoustic Transducer, or EMAT. This sensor utilizes ultrasonic waves conducted electromagnetically through metal plating. It effectively penetrates layers of paint, rust, and up to 150mm of steel. This capability provides a level of defect detection far exceeding traditional visual inspections performed by human technicians.
5Operational Efficiency Gains
The Komodo system operates 50 times faster than traditional manual inspection methods. By reaching tight, inaccessible spaces, the robots ensure thorough coverage that human workers cannot comfortably achieve. Furthermore, every scan is recorded, creating a permanent digital log of inspection data that informs future maintenance cycles and long-term structural health assessments for vessels.
6Future Underwater Expansion
Currently, the Komodo system is restricted to ships positioned in drydock environments. However, Gecko Robotics is actively developing a new tool named Axolotl. This upcoming technology is designed to operate below the waterline, potentially enabling full hull inspections without the necessity of moving ships into drydocks or using auxiliary floating dry docks.
7Technological Shift in Defense
The Navy has previously utilized various uncrewed surface vessels, but using drones specifically for structural repair marks a tactical shift. By automating the detection of corrosion and cracks, the military reduces the reliance on manual labor for hazardous tasks. This transition highlights a broader trend of integrating specialized robotics into core defense infrastructure.
8Long-term Maintenance Impact
The $300 million investment reflects the Navy's commitment to modernizing maintenance through high-tech automation. By shifting from reactive, manual inspections to data-driven, AI-assisted diagnostics, the military optimizes fleet readiness. This technological adoption ensures that vessels return to sea faster, maintaining operational superiority while simultaneously controlling the high costs associated with maritime corrosion.
Original article: SlashGear — US Navy Deploys Gecko Robotics for Advanced Ship Hull Inspections