Introduction

The future of beyond visual line of sight (BVLOS) drone operations is on the horizon, and Xplorate has been waiting. With the U.S. FAA proposing new rules to enable routine BVLOS flights, Xplorate’s cutting-edge SDO50V3 unmanned helicopter and rigorous operating standards position us as a turnkey BVLOS UAS provider ready to lead the US market.

In this brief, we highlight how the SDO50V3’s technical prowess – from endurance and range to detect-and-avoid safety – aligns with the FAA’s vision, and how Xplorate’s maintenance and operational practices (guided by the IOGP 696 standard) meet or exceed the proposed requirements. From powerline corridors to pipeline networks, Xplorate is primed to deliver safe, efficient infrastructure inspections that go above and beyond (quite literally) visual line of sight.

FAA’s Proposed BVLOS Regulations: A Quick Overview

The FAA’s proposed BVLOS rule is set to normalise long-range UAS operations by laying out clear requirements across several areas. In simple terms, the rule will require:

• Robust Flight Operations: Drones must be operated with strict safety procedures and qualified personnel overseeing missions.

• Airworthiness Standards: UAVs should be built and maintained to high reliability standards, similar to traditional aircraft, to ensure they are airworthy for extended missions.

• Detect-and-Avoid Capabilities: Operators must keep drones safely separated from other aircraft, which means onboard or offboard systems to detect other airspace users and take evasive action if needed.

• Operational Authorisations & Training: Operators will need proper certification and accountability, ensuring remote pilots are trained and organisations have approval to conduct BVLOS flights responsibly.

• Security & Control: Strong command-and-control links and cybersecurity measures to prevent interference or hijacking of the UAV during BVLOS operations.

• Data Reporting & Record-Keeping: Comprehensive logging of flights, maintenance, and any incidents, to facilitate oversight and continuous safety improvement.

These requirements might sound technical, but in essence they boil down to one goal: BVLOS drones must be as safe and reliable as manned aviation. Xplorate anticipated this direction from the start. Our approach has been to hold our technology and teams to aviation-grade standards, so that we not only comply with these upcoming rules but actually stay ahead of them.

SDO50V3: A UAV Built for Long-Range, Safe Missions

At the heart of Xplorate’s BVLOS solution is the SDO50V3, a high-performance unmanned helicopter designed for extended missions. This aircraft’s capabilities align perfectly with the FAA’s safety expectations:

• Long Endurance & Range: Powered by a fuel-efficient jet turbine engine, the SDO50V3 can fly for up to 3 hours continuously and cover distances of 100+ km. This endurance far exceeds that of typical small drones and is ideal for inspecting long linear assets like powerlines and pipelines without needing to stop and refuel.

• Heavy Payload Capacity: With the ability to carry up to 40 kg of payload (including sensors and fuel), the SDO50V3 can host advanced cameras, LiDAR, thermal sensors, and other safety equipment simultaneously. This means one flight can gather multiple data types (imagery, infrared, mapping data, etc.) in one go – a force multiplier for infrastructure analytics.

• Detect-and-Avoid Technology: Safety is built-in. DAA systems have already been tested. The aircraft is equipped with a TSO ADS-B transponder (Mode S) to broadcast its position to other airspace users and integrate into air traffic awareness systems. In practical terms, this feature helps keep the drone visible to other aircraft and air traffic control, addressing the FAA’s requirement for collision avoidance. The SDO50V3’s dual high-resolution pilot cameras (forward and downward views) also give our remote pilots excellent situational awareness.

• Redundant Systems & Reliability: The SDO50V3 is engineered with redundant avionics and fail-safes for critical systems. For example, its autopilot and sensor suite have backup components, and as a helicopter it even offers autorotation capability – the ability to land safely under gravity in the rare event of an engine faiure. "The best part is no part" Elon Musk. No parachute necessary. This robust design, built to manned aviation-grade manufacturing standards, ensures high reliability in the field. In fact, the SwissDrones platform (SDO50) has been authorised to fly BVLOS in numerous jurisdictions already, a testament to its safety pedigree.

• Secure Long-Distance Control: BVLOS missions demand rock-solid communication. The SDO50V3 supports multiple encrypted data link options – from radio frequencies (UHF) to 4G/LTE and even satellite links – to maintain control and data transmission over long ranges. This multilayered comms approach aligns with the FAA’s emphasis on secure, reliable control for drones far from their operators.

All these capabilities make the SDO50V3 a natural fit for the new BVLOS era. It’s essentially a small unmanned helicopter with the performance and safety features of a full-size aircraft, but at a fraction of the cost and environmental impact. In fact, our long-range drone uses about 90% less fuel and 75% lower operating cost per hour compared to a crewed helicopter, while carrying 10× the payload of typical small quadcopter drones. This combination of efficiency and muscle means Xplorate can tackle large-scale inspection jobs quickly, safely, and economically.

World-Class Operations & Maintenance (IOGP 696 Compliance)

Technology alone isn’t enough – how you operate and maintain that technology is equally critical, especially under stringent BVLOS rules. Xplorate distinguishes itself by running a tight ship on par with the best manned aviation operators. We have adopted the International Association of Oil & Gas Producers (IOGP) 696 recommended practices as our guiding standard for unmanned aircraft operations. IOGP 696 provides best-practice guidelines for the safe and effective management of Remotely Piloted Aircraft Systems, covering everything from pilot training and risk assessment to maintenance protocols.

What does this mean for our clients and regulators? It means Xplorate’s operations meet the highest global benchmarks for safety and reliability. We are IOGP696 compliant in our procedures, and our flight operations have been approved to the highest applicable standards of IOGP and major oil & gas “supermajors”. In practice, this translates to:

• Aviation-Grade Crew & Protocols: Our BVLOS flights are planned and executed by experienced, licensed pilots and aviation professionals – not hobbyists. We operate to full aviation industry standards, so every mission is conducted with rigorous pre-flight checks, real-time monitoring, and adherence to established airspace rules. This professionalism is exactly what the FAA expects as BVLOS becomes mainstream.

• Proactive Maintenance & Record-Keeping: Xplorate follows a strict maintenance schedule guided by manufacturer requirements and IOGP best practices. Every aircraft is kept in peak condition with detailed logs of inspections, part replacements, and software updates. The FAA’s proposed requirement for robust record-keeping is essentially already business-as-usual for us – we’ve been doing it from day one.

• Comprehensive Safety Management: We carry out thorough risk assessments for each mission (evaluating airspace, weather, terrain, and any ground risks along a route) and maintain contingency plans for emergencies. Our operations manual and safety management system are built to OGARP standards (Oil & Gas Aviation Recommended Practices), meaning we continuously measure and improve safety performance. This commitment to safety and compliance is on the same level as the highest requirements of our global customers in the oil & gas industry, and it certainly satisfies the FAA’s expectations for BVLOS operations.

By aligning with IOGP 696, Xplorate essentially exceeds many of the FAA’s proposed BVLOS requirements. We didn’t wait for regulations to tell us what “good” looks like – we proactively adopted the toughest standards available. This approach gives regulators confidence and gives our clients peace of mind that every Xplorate BVLOS mission is executed with uncompromising safety and reliability.

Transforming Powerline and Pipeline Inspections

One of the most exciting applications of BVLOS flight is the inspection of long linear infrastructure, such as electrical powerlines and oil & gas pipelines. These assets often stretch across remote or hard-to-access areas, and traditionally they’ve been monitored by crews in manned helicopters or small drone teams leapfrogging along sections (with costly ground support). Xplorate’s BVLOS solution is a game changer here, offering a new level of efficiency, coverage, and data quality for infrastructure operators.

Imagine a utility company needing to survey hundreds of kilometres of high-voltage transmission lines for storm damage or vegetation encroachment. With the SDO50V3, Xplorate can dispatch a single aircraft to autonomously fly the entire route beyond visual line of sight, all while the remote pilot (Human in the loop) and data specialists monitor from a central location. The drone’s long endurance means it can inspect far-flung tower spans in one mission, and its heavy payload means it carries high-zoom electro-optical cameras and thermal imagers to spot issues like cracked insulators or overheated components. Throughout the flight, the onboard ADS-B keeps the drone electronically visible to other airspace users, and our team can adjust the flight path if air traffic is detected – fulfilling the “see and avoid” mandate even dozens of kilometers away from the pilot. The result is a thorough inspection accomplished faster, safer, and at lower cost than traditional methods. No pilots are put at risk in low-altitude helicopter flights, and there’s minimal disruption to the environment or local communities.

The same goes for pipeline inspection. In fact, Xplorate achieved a world’s first RPAS 500+ km pipeline inspection using our long-range drone technology. During this project, we demonstrated how a BVLOS drone can overfly extensive pipeline corridors to check for things like leaks, unauthorised activities near the right-of-way, or environmental changes, all in a single coordinated operation. Our data platform can even live-stream findings to analysts, so issues are identified in near-real-time. For pipeline operators, this means discovering potential problems early and responding before they escalate into incidents – a huge win for safety and uptime. And because the SDO50V3 burns a fraction of the fuel of a manned helicopter for the same job, these inspections dramatically cut carbon emissions and fuel costs, supporting corporate sustainability goals while saving money.

Crucially, the FAA’s upcoming BVLOS rules will make these kinds of operations routine. No more experimental waivers or one-off approvals – infrastructure companies and traditional operators can partner with Xplorate to set up regular BVLOS patrols of their assets under a clear regulatory framework. Xplorate is already authorised for BVLOS operations in Australia (under CASA) and has even secured an FAA Part 91 BVLOS exemption for trial operations in the US, showcasing our leadership in this domain. As soon as the new rules take effect, we are ready to hit the ground running with turnkey inspection services that cover everything from obtaining flight approvals to delivering actionable inspection reports. In fact, we already have programs scheduled prior. It’s truly a new era for maintaining critical infrastructure, and Xplorate is proud to be at the forefront.

Leading the BVLOS Revolution

With technology and standards working hand-in-hand, Xplorate has positioned itself as a leader in BVLOS UAS operations. We offer an end-to-end solution: a world-class unmanned aircraft in the SDO50V3, an expert team versed in aviation-grade operations, and a track record of safety and innovation that is second to none. Our commitment to IOGP 696 operating standards and our embrace of advanced features like ADS-B transponders and redundant flight systems mean that regulators and clients can trust us to deliver missions that are fully compliant and exceptionally safe.

As the FAA moves to finalise its BVLOS regulations, Xplorate is not just ready to comply – we’re already there. We’ve proven the concept across continents by pioneering projects in remote pipeline and maritime operations, and we’ve built a service model that makes adopting BVLOS inspection and monitoring truly turnkey for our customers. Whether it’s surveying powerlines after a storm, patrolling miles of pipeline for preventive maintenance, or any number of large-scale aerial tasks, Xplorate’s BVLOS solution is ready for deployment.

Conclusion: The proposed FAA BVLOS rule is poised to unlock incredible possibilities for drones in the national airspace. Xplorate is excited about this future – we’ve invested in the right aircraft, the right practices, and the right people to ensure BVLOS operations are done right. By combining the SDO50V3’s technical excellence (endurance, range, payload, and safety systems) with our unwavering commitment to top-tier maintenance and safety standards, Xplorate stands out as a leading BVLOS partner for industry and government alike. We’re not just keeping up with regulations; we’re setting the benchmark for what BVLOS operations can achieve. When you think of turnkey BVLOS UAS services in the US – think Xplorate, the company that’s already flying beyond the horizon.