Fiber Optic Sensing for Structural Health Monitoring in Aerospace with FPGA-Based Platforms

In aerospace engineering, structural health monitoring demands lightweight, high-speed, and highly accurate measurement systems. One breakthrough technology enabling this is NASA’s  Fiber Optic Sensing System (FOSS) — capable of delivering thousands of real-time strain, deformation, and temperature measurements along a single optical fiber thinner than a human hair.

Traditionally, engineers relied on bulky sensors, extensive wiring, and racks of electronics, which added weight and complexity to aircraft and spacecraft. By contrast, distributed fiber optic sensing systems replace much of this infrastructure with a single optical fiber that can deliver up to 2,000 high-fidelity data points in real time — critical for monitoring fuel efficiency, structural integrity, and overall flight safety.

FPGA Platforms for Real-Time Signal Acquisition

Processing such vast data streams requires deterministic, low-latency signal acquisition. This is where FPGA-based platforms like the Red Pitaya STEMlab 125-14 play a crucial role.

Instead of relying on traditional operating systems, the platform was adapted to run a bare-metal FPGA configuration, eliminating software delays and ensuring real-time signal processing. This enabled fiber optic strain and temperature measurements to feed directly into aerospace control systems without latency — a key requirement for advanced research projects like flexible wing structures and inflight load monitoring.

Applications in Flight and Space Systems

Distributed fiber optic sensing is proving essential for both atmospheric flight and space missions. Key applications include:

• Inflatable decelerators (LOFTID project): live thermal mapping during re-entry, captured across hundreds of sensing points along the structure.
• Composite overwrapped pressure vessels (COPVs): real-time strain and temperature monitoring for cryogenic fuel storage under extreme mechanical and thermal loads.
• Experimental aircraft (X-56 Testbed): precise measurement of wing deformation to develop safer and more efficient flight technologies.

Each of these use cases demonstrates how FPGA-powered fiber optic sensing systems provide the reliability and adaptability needed in mission-critical aerospace environments.

Compact, Modular, and Scalable Instrumentation

Unlike traditional aerospace instrumentation racks, compact FPGA platforms like Red Pitaya bring high-performance test and measurement into a small, modular form factor. This reduction in weight and complexity not only saves cost but also translates into sustainability benefits: lighter aircraft during testing consume less fuel, while higher-fidelity simulations and monitoring reduce the number of required test flights.

For aerospace teams, this balance of affordability, flexibility, and real-time precision is what makes fiber optic sensing a viable solution for next-generation structural health monitoring.

Redefining Aerospace Structural Health Monitoring

The integration of fiber optic sensing with FPGA-based signal acquisition marks a turning point in how aerospace systems are monitored. From inflight strain mapping to cryogenic fuel tank monitoring, these systems are enabling lighter, smarter, and safer designs.

The same principles are already being adapted across industries where distributed sensing and real-time data acquisition are critical — including oil and gas, power generation, and maritime systems.

FAQ Section

Q1: What is NASA’s Fiber Optic Sensing System (FOSS)?
A: FOSS is an advanced measurement system that uses lightweight fiber optic cables to capture thousands of real-time data points for monitoring strain, temperature, shape deformation, and loads on aircraft and spacecraft.

Q2: How does Red Pitaya STEMlab support FOSS?
A: Red Pitaya’s STEMlab 125-14 platform runs a custom bare-metal signal acquisition stack that processes FOSS data with ultra-low latency, enabling real-time control and monitoring even in extreme environments.

Q3: What are the benefits of using fiber optic sensing in aerospace?
A: Fiber optic sensing reduces system weight, wiring complexity, and sensor bulk, while delivering high-resolution data that improves fuel efficiency, structural health monitoring, and safety for aircraft and spacecraft.

Q4: Can Red Pitaya STEMlab be used in other industries?
A: Yes — the same open-source, modular hardware is used globally in research labs, quantum sensing, education, and industrial applications where real-time signal processing and customization are key.