Scaling UAV and Robotics Programs: Insights from Industry Leaders

The 2024 Drone & Robotic Operators Forum, co-located with the Energy Drone & Robotics Summit, served as a dynamic platform to explore the evolving roles of UAVs and robotics in energy and infrastructure. During the UAV/Robotics Operator Roundtable, “Taking Your Programs Further & Scaling to the Next Level,” industry leaders shared their successes, challenges, and insights on scaling UAV and robotics programs. Panelists included:

  • Scott McGowan, NetZero Aerial

  • Dustin Waller, Oxy

  • John Fowler, Cyberhawk

  • Genevieve Dacambra, Suncor Energy

  • Moderator Sean Guerre, Energy Drone & Robotics Coalition

Their collective experiences highlight best practices and innovative approaches that can help organizations unlock the potential of UAV and robotics technologies.

Key Use Cases Driving UAV and Robotics Expansion

The session kicked off with the panelists discussing standout projects from 2023. These examples illustrated the versatility of UAVs in solving complex challenges:

Revolutionizing Haul Road Design

Genevieve Dacambra shared how Suncor Energy leveraged drones to reduce tire wear on haul trucks, some of which have $400,000 tires. Working with a university and a service provider, Suncor used UAVs to analyze road grades and seasonal impacts. The insights helped redesign the haul roads, significantly reducing tire damage and costs. This project, part of a broader 138-use-case portfolio, demonstrated how targeted UAV initiatives can deliver substantial ROI while improving reliability and safety.

Navigating Regulatory Challenges for Innovative Solutions

Scott McGowan recounted a unique lidar scanning project to optimize wind turbine blade transportation via barge. While the project faced logistical and regulatory hurdles, the team successfully captured critical data. Although the collected lidar data presented challenges due to barge movement, the project showcased the importance of adaptability and creative problem-solving in UAV operations.

Beyond Visual Line of Sight (BVLOS) Innovations

John Fowler highlighted Cyberhawk’s work with hydrogen-powered drones for BVLOS inspections of transmission lines. These drones enabled extended flight times, significantly enhancing efficiency and reducing the need for on-ground personnel. Fowler emphasized how BVLOS capabilities represent the future of asset inspections, improving safety and cost-effectiveness for energy utilities.

Strategic Approaches to Scaling UAV Programs

Scaling UAV operations requires deliberate strategies, combining technology, partnerships, and organizational alignment.

Centralizing Operations for Consistency and Growth

Dacambra described how Suncor Energy’s centralized drone program, established as a “Center of Excellence,” ensures regulatory compliance and operational consistency across vast geographic areas. By integrating internal assets and external vendors, Suncor scaled to handle more than 4,000 missions annually while ensuring agility and adherence to safety standards.

Hybrid Models: A Flexible Approach

Suncor’s hybrid model offers an ideal balance of in-house expertise and outsourced partnerships. The company maintains stringent vendor vetting criteria, including pilot experience, safety records, and data management capabilities. This approach fosters long-term, multi-year partnerships with service providers that demonstrate adaptability and alignment with Suncor’s goals.

In-House Expertise for Rapid Deployment

Oxy has worked to build a robust in-house drone program. Waller explained how the company relies on its 40 trained pilots, including eight full-time specialists, to quickly address diverse operational needs. This approach enables rapid response and comprehensive data collection tailored to multiple business units. Oxy’s in-house data library, which organizes and shares UAV data across departments, further amplifies the program’s impact.

Overcoming Data Management Challenges

A recurring theme was the challenge of managing and processing massive amounts of data generated by UAVs and robotics.

Proprietary Formats and Standardization

McGowan noted the complexities introduced by proprietary data formats and the need for software capable of integrating outputs from diverse sensors, including lidar and thermal imaging. These challenges emphasize the importance of selecting interoperable tools and fostering collaboration between software providers and asset owners.

Maximizing Value Through Accessibility

Waller shared how Oxy addresses data challenges by leveraging streaming services to tile orthomosaics directly into its GIS system. This approach minimizes internal storage burdens while ensuring easy access to UAV data across the organization.

Historical Data for ROI and Insights

Fowler highlighted the value of historical data in justifying ROI. For example, by comparing current and past imagery, organizations can make informed decisions about asset maintenance and defer unnecessary replacements.

ROI as a Driver for Scaling

The panelists discussed how ROI remains the primary metric for justifying UAV program expansion. Examples included:

  • Cost Avoidance in High-Risk Inspections: Using drones for offshore flare inspections, Suncor avoided costly shutdowns while reducing safety risks. Projects like these, which eliminate confined-space entries and working-at-heights exposures, simultaneously deliver financial and safety benefits.

  • Accelerating Workflows: McGowan’s team demonstrated how UAVs could reduce survey timelines from months to days. For example, a solar project requiring a traditional survey that took months  was completed in just a day and a half using drones, highlighting significant time and cost savings.

  • Broadening Use Cases: Even simple applications like capturing aerial facility images can create unexpected value, Waller explained. Departments ranging from HR to safety teams benefit from access to these visualizations, enhancing organizational buy-in for UAV programs.

The Future of UAV and Robotics Programs

The session concluded with discussions about the future of UAV and robotics programs, emphasizing:

  1. Interoperability: Developing systems that integrate data from drones, ground robotics, and other sources for a complete operational picture.

  2. AI and Digital Twins: Leveraging AI to process drone data and build digital twins for predictive maintenance and operational modeling.

  3. Continuous Innovation: Investing in training and staying current with emerging technologies to maintain competitive advantages.

This operator roundtable from the 2024 Drone and Robotic Operators Forum highlighted how UAVs and robotics are transforming industries through innovation, efficiency, and safety improvements. Whether through centralized models, hybrid partnerships, or fully in-house teams, organizations are finding diverse ways to scale their programs. By addressing challenges such as data management and regulatory compliance, companies can unlock the full potential of UAV and robotics technology.

With the rapid pace of change, one message was clear: scaling UAV programs isn’t just about flying drones—it’s about building an ecosystem of people, technology, and partnerships that work together to drive value.

Join us in 2025

Get signed up for the 2025 Energy Drone & Robotics Summit in Houston, Texas, June 16-18, 2025. And stay tuned for details about the Drone & Robotics Operators Forum, which will be co-located with the summit.