Pitot Probe Icing Testing & Air Data Probe Testing

Pitot probes, pressure probes, and related air data system components must operate reliably under environmental conditions such as icing.

We perform controlled icing wind tunnel testing of pitot probes, pitot-static probes, pressure probes, pressure rakes and related air data system components to evaluate blockage risk, measurement performance, ice protection concepts and pre-certification readiness.

Why Pitot Probe Icing Testing Matters

Accurate air data is essential for safe and stable operation of airborne systems. Under icing conditions, pitot probes and air data probes can experience blockage, measurement errors or complete loss of usable pressure data.

Early pitot probe icing testing is therefore critical to:

  • identify design weaknesses
  • evaluate ice protection system performance
  • compare different probe geometries and concepts
  • reduce risk before entering certification processes

Aircraft Component Icing Testing for Sensors and Probes

We perform aircraft component icing testing for pitot probes, pitot-static probes, pressure rakes and related air data system components across a range of sizes and geometries, provided they fit within the test section.

Typical configurations include:

  • Probes with characteristic diameters up to approximately 30 mm
  • Lengths up to approximately 300 mm (depending on mounting configuration)
  • Smaller probes (e.g. 5–10 mm diameter) tested in parallel

For small-scale systems, multiple probes can be tested simultaneously, enabling efficient comparison of probe geometries, heating concepts and measurement performance within a single test campaign.

If required, the test section can be adapted to accommodate larger components, with corresponding adjustments to operating conditions.

Performance Testing of Pitot-Static Probes and Air Data Probes

Pitot-static probe testing and air data probe testing are used to evaluate how probe geometry, openings and pressure channels behave under controlled icing conditions.

We assess:

  • Ice accretion on probe geometry and openings
  • Blockage and degradation of pressure measurement capability
  • Sensitivity of different geometries to icing

Testing under varying temperature, airflow and droplet conditions allows comparison of probe performance across realistic operating scenarios.

Ice Protection System Testing for Pitot Probes and Aircraft Sensors

We support the evaluation of active and hybrid ice protection systems integrated into pitot probes and pressure measurement devices.

This includes:

  • Testing of electrothermal ice protection systems under icing conditions
  • Variation of heating power and evaluation of resulting effectiveness
  • Correlation between heating performance, ice accretion, and probe functionality
  • Comparison of protected and unprotected probe geometries

Our experience with ice protection systems allows us to assess where protection is required, how it should be applied, and how system performance can be validated under realistic conditions.

Measurement, Blockage and Ice Accretion Evaluation

Testing is supported by direct observation and functional measurement:

  • Pressure signal evaluation and comparison with reference conditions
  • Visual and camera-based assessment of blockage and ice accretion
  • High-speed imaging of ice formation and shedding
  • Correlation of icing behavior with probe functionality

This allows verification of whether a probe continues to deliver meaningful measurements under icing exposure.

Air Data Probes in the Icing Wind Tunnel: Understanding the Challenges

Testing pitot probes under icing conditions is inherently challenging due to the interaction between geometry, flow conditions, and ice formation.

Even small design variations can significantly affect:

  • how ice accumulates on the probe
  • whether openings remain free or become blocked
  • how effective an ice protection system is under different conditions

In many applications, especially for small-scale airborne systems, additional constraints apply. Limited available power requires highly efficient ice protection concepts, where even small improvements in design or operation can have a significant impact.

At the same time, development cycles are becoming increasingly short, with rapid iteration of components and systems. This makes it essential to evaluate designs efficiently and identify performance limitations early in the development process.

Early-stage testing often reveals performance limitations that are not obvious from design alone. Controlled experiments are therefore essential to identify critical design parameters and improve robustness before entering certification processes.

Aircraft Sensor Qualification Testing Support

Our approach enables rapid screening of different probe designs and technologies before formal certification.

This includes:

  • Comparative testing of multiple probe geometries in a single campaign
  • Evaluation of different ice protection concepts
  • Identification of performance limits under controlled conditions
  • Pre-certification support for aerospace sensor development

This allows engineering teams to iterate designs efficiently and focus development efforts where they are most effective.

Applications for Pitot Probe and Air Data Probe Testing

Icing wind tunnel testing can be applied to pitot probes, pitot-static probes, pressure probes, pressure rakes, air data system components, humidity sensors and other aircraft sensor hardware exposed to icing conditions.

The same test logic can be adapted across different component types: expose the device to controlled icing conditions, observe ice accretion and blockage behavior, measure functional performance, and compare design variants or ice protection concepts under repeatable conditions.

Development of New Probe Geometries and Concepts

Pitot probe testing and air data probe testing can be used during early development to compare different probe geometries, opening layouts, pressure channel configurations and installation concepts. Controlled icing tests help identify which designs are more sensitive to ice accretion, blockage or unstable pressure measurement. This supports engineering decisions before committing to more complex prototypes or formal qualification campaigns.

Validation of Ice Protection Systems

For heated probes and protected sensor concepts, icing tests can be used to evaluate whether the ice protection system maintains functional performance under defined icing conditions. Parameters such as heating power, exposed geometry, airflow, temperature and liquid water content can be varied to compare protected and unprotected configurations. This is relevant for electrothermal ice protection, hybrid concepts and low-power systems for UAVs, drones and compact aerospace sensor packages.

Evaluation of Pressure Measurement Devices Under Icing Conditions

Pressure measurement devices can be evaluated for blockage risk, response stability and measurement degradation during icing exposure. This includes pitot probes, pitot-static probes, pressure probes, pressure rakes and related air data system components. The tests can combine visual ice accretion observation with functional pressure measurement, which allows engineers to connect visible ice formation with actual sensor performance.

Aircraft Sensor Qualification Testing Support

Aircraft sensor qualification testing often requires a clear understanding of how components behave before formal certification or qualification procedures begin. Icing wind tunnel testing can support pre-certification work by screening probe designs, comparing ice protection strategies and identifying performance limits under controlled conditions. The goal is not only to show whether a component works, but to understand why it works, where it fails and which design parameters should be improved before the next development step.

Relevant Industries

Relevant industries and use cases include: