VX Aerospace contributed composite design and manufacturing expertise to the development of the robotic inspection system for the San Giorgio Bridge in Genoa, Italy. Working with an international team of engineering and technology partners, VX Aerospace supported the development and manufacture of large carbon-fiber structural beams used by the automated bridge monitoring system.
The project demonstrated how aerospace composite manufacturing techniques can be applied to critical infrastructure applications requiring lightweight, high-stiffness structures capable of supporting advanced sensing and robotic systems.
Following the collapse of the Morandi Bridge in 2018, the San Giorgio Bridge was designed and constructed as a next-generation transportation structure incorporating advanced monitoring technologies intended to improve long-term safety and maintenance.
As part of the bridge’s monitoring strategy, an automated robotic inspection system was developed to continuously evaluate the condition of the structure using cameras, sensors, and data processing algorithms. The system allows operators to identify potential issues and perform preventative maintenance before problems become critical.
The resulting robotic inspection platform is believed to be one of the first systems of its kind designed specifically for continuous infrastructure monitoring on a bridge of this scale.
The robotic inspection system required a structural solution that could extend beneath the bridge deck while carrying sensors and inspection equipment over long distances.
The inspection arms needed to provide exceptional stiffness while remaining lightweight enough to support reliable robotic operation. The final system incorporated fixed and retractable beam sections that allow the inspection system to reach areas of the bridge that would otherwise be difficult to access.
When fully extended, the inspection beam reaches approximately 56 feet in length. The complete RobotInspection system weighs approximately 4,850 pounds and operates along rails mounted to the bridge structure.
Meeting the structural requirements for the inspection beam demanded a solution that balanced weight, stiffness, durability, manufacturability, and long-term operational performance.
To satisfy the demanding structural requirements of the robotic inspection system, the project team utilized advanced composite materials and manufacturing approaches more commonly associated with aerospace and aeronautical applications.
VX Aerospace worked with the project design team to develop and manufacture the large carbon-fiber inspection beams used by the robotic system. The resulting structures were designed to provide the high stiffness-to-weight ratio required by the bridge designers while supporting the operational requirements of the inspection platform.
In cooperation with the University of South Carolina and Ingersoll Machine Tools, VX Aerospace manufactured the composite beam structures using fiber-reinforced polymer materials optimized for lightweight structural performance.
The San Giorgio Bridge project required the manufacture of some of the largest composite structures ever produced by VX Aerospace.
Working from large-format tooling, VX Aerospace manufactured the carbon-fiber inspection beams using aerospace-derived composite fabrication methods. The project utilized advanced additive manufacturing technologies to create the tooling required for production of the large structural components.
The composite beams were manufactured using large-format 3D-printed tooling before being cured in VX Aerospace’s 40-foot oven and prepared for shipment to Italy. The completed structures combined low weight, high stiffness, and long-span structural performance while meeting the demanding requirements of the robotic inspection system.
The project highlighted VX Aerospace’s ability to apply aerospace composite manufacturing techniques to large-scale structural applications outside the traditional aviation market.
The San Giorgio Bridge robotic inspection system was developed through collaboration between multiple international organizations specializing in robotics, infrastructure, advanced manufacturing, and composite engineering.
Project participants included:
The Italian Institute of Technology contributed robotics expertise and system development, while Camozzi Group provided advanced manufacturing and system integration capabilities. VX Aerospace contributed composite manufacturing expertise and worked with project partners to develop and manufacture the large structural inspection beams used by the robotic monitoring system.
The San Giorgio Bridge project demonstrated how aerospace-grade composite materials and manufacturing processes can be applied to critical infrastructure applications.
By contributing to one of the world’s most advanced robotic bridge inspection systems, VX Aerospace expanded the application of its composite manufacturing expertise beyond aerospace and defense markets into the fields of infrastructure monitoring, robotics, and structural health management.
The project also demonstrated VX Aerospace’s capability to execute large-scale composite manufacturing programs requiring advanced tooling, precision fabrication, and collaboration with international engineering teams.
Through the successful manufacture and delivery of the composite inspection beams, VX Aerospace helped support a system designed to improve bridge monitoring, maintenance planning, and long-term infrastructure safety.