Angle-of-Attack Covers: Protecting the Sensor That Protects You
Key Takeaways
- Angle-of-attack sensors are safety-critical components that continuously feed lift data to the aircraft's air data computer, and damage from ramp activity, pressure washing, or tool contact can contribute to stall events.
- The FAA has specifically highlighted the risk of AOA sensor damage during ground operations and maintenance, making protective covers a direct response to agency guidance rather than just a convenience item.
- Sesame Technologies AOA covers are built from heavy-gauge anodized aluminum with non-scratch bases, captive screws, heat venting, and bright red coloring with warning streamers – features designed to prevent both sensor damage and inadvertent pre-flight omission.
- Lower-cost covers made from polyester or vinyl can melt or ignite when exposed to heat, potentially causing the very sensor damage they are meant to prevent – making the premium cost of a Sesame Technologies cover a worthwhile trade-off.
- Sesame Technologies offers six models spanning business jets and wide-body commercial aircraft, including the new Executive Series AOA-EX-Guard and AOAC-5-EX for high-performance business aviation, and four Signature Series models for Boeing and Lockheed platforms.
'Every flight begins – and ends – on the ground. And while aviation safety conversation tends to focus on what happens in the air, some of the most consequential damage to aircraft systems occurs right on the ramp – during maintenance, servicing, and routine ground handling.
Among the components most vulnerable to this kind of incidental damage is the angle-of-attack sensor, a small yet safety-critical assembly that plays a direct role in keeping pilots aware of their aircraft's performance limits. Protecting it between flights isn't optional – it's essential.
In this article, we'll cover why angle-of-attack sensor protection matters, why Sesame Technologies is the leading choice for AOA covers, and how to find the right model for your aircraft and operating environment.
Why Use an Angle-of-Attack Cover?
The angle of attack (AOA) is the angle between the wing and the oncoming airflow. During flight, small vanes on the AOA sensor continuously align themselves with that airflow, sending critical data to the aircraft's air data computer. When those vanes are damaged or compromised, the consequences can be serious – faulty AOA readings can contribute to loss-of-lift events, more commonly known as stalls.
That makes protecting the AOA sensor a genuine flight safety priority, not just a maintenance best practice. An angle-of-attack cover acts as a physical barrier against pressure wash exposure, tool contact, and the general ramp activity that can compromise vane integrity between flights.
The FAA has underscored this point directly. In a 2019 memo, the agency stated that "it is imperative that all operators are aware of the criticality of AOA sensors and the potential for damage during normal operations, maintenance procedures, servicing procedures, and any other procedures around an aircraft where damage to an AOA sensor could occur." Using a quality AOA cover is one of the simplest, most cost-effective ways to take that guidance seriously.
Why Choose Sesame Technologies?
Not all AOA covers are created equal, and Sesame Technologies, Inc. has spent years setting the standard for what a properly engineered cover looks like. Their designs reflect rigorous research and development, thorough testing, and an attention to detail that shows up in every feature.
All Sesame Technologies AOA covers are constructed from heavy-gauge anodized aluminum, which helps minimize the risk of vane deformation during maintenance activities such as high-pressure washing. Each cover features a non-scratch, heat-resistant protective base, captive screws for straightforward installation and removal, and venting to promote heat dissipation. Their signature eye-catching red color ensures covers are never inadvertently left on before flight – a simple but critical design choice. Most models also include a NAS-approved warning streamer with part number identification for added preflight visibility.
For severe-duty applications, select models take protection further with a Nomex® cover equipped with flame-retardant hook-and-loop fasteners, providing an additional layer of defense against heat and environmental hazards while still allowing full interior access during installation and removal.
Is a Premium Angle-of-Attack Cover Worth the Extra Cost?
Lower-cost AOA covers may be tempting at first glance, but they come with real trade-offs. Covers made from polyester, vinyl, or other lightweight materials are susceptible to melting or igniting when exposed to high heat – creating the very risk they're supposed to prevent, and potentially causing thousands of dollars in sensor damage or replacement costs.
By contrast, a Sesame Technologies cover is built to last. The durability of heavy-gauge anodized aluminum means fewer replacements over time, and the flame-resistant construction eliminates one of the most common failure modes of cheaper alternatives. The cost difference between Sesame Technologies' covers and lower-quality competitors is minimal. The difference in protection is not.
What AOA Cover Models Does Sesame Technologies Offer?
Sesame Technologies currently offers six models of angle-of-attack covers, spanning everything from business jets to wide-body commercial airliners. The two newest additions – the AOA-EX-Guard and AOAC-5-EX – are part of Sesame Technologies' Executive Series, a pioneering line of ground support equipment engineered specifically for today's high-performance business and luxury aircraft.
Executive Series Models
AOA-EX-Guard – EX Angle of Attack Vane Cover
The AOA-EX-Guard is a premium hard-shell protective enclosure designed specifically for AOA sensors on business jets. Built with a reinforced EX-grade high-impact polymer shell, it guards against foreign object damage, moisture infiltration, and the kind of incidental contact that can occur in busy MRO environments. A simple clamp-style attachment secures the cover without placing stress on the sensor assembly, and a safety streamer is included for clear preflight visibility.
Like all Executive Series products, the AOA-EX-Guard comes pre-fitted with positive attachments for Sesame Technologies' Safety Lanyard System, enabling fast, secure connections across the full Executive Series GSE lineup.
The AOA-EX-Guard is compatible with a wide range of business jet platforms, including Bombardier Challenger and Global series aircraft, Cessna Citation variants, Gulfstream models from the G100 through the G700, Dassault Falcon series jets, Embraer Legacy and Phenom models, Hawker Beechcraft, HondaJet, Pilatus PC-12 and PC-24, and more.
AOAC-5-EX – EX Universal Angle of Attack Cover
The AOAC-5-EX offers a flexible universal fit across a similarly broad range of executive aircraft platforms. Where the AOA-EX-Guard's hard-shell construction is optimized for maximum impact protection, the AOAC-5-EX is engineered for versatility – its universal design accommodates a wide variety of AOA vane profiles, making it an excellent choice for MRO teams working with diverse fleets.
Constructed from rugged EX-grade engineered composite, the AOAC-5-EX is moisture- and UV-resistant for reliable outdoor ramp use. Its streamlined profile reduces the risk of snagging during servicing, and like the AOA-EX-Guard, it comes pre-fitted with attachments for Sesame Technologies' Safety Lanyard System. The AOAC-5-EX covers a very similar range of executive aircraft as the AOA-EX-Guard, spanning Bombardier, Cessna, Cirrus, Daher-Socata, Dassault, Embraer, Gulfstream, Hawker Beechcraft, HondaJet, Pilatus, and more.
Signature Series Models
The Sesame Technologies Signature Series models are designed for Rosemount and Gulton Statham (Conrac) vanes on commercial and military aircraft, with each covering a specific range of Boeing and other airframes. All four share the same core construction – heavy-gauge anodized aluminum, a non-scratch heat-resistant base, captive screws, and a NAS-approved warning streamer with part number identification – with fit compatibility being the primary distinction between them.
R/C-AOAC-2
The R/C-AOAC-2 fits Rosemount and Gulton Statham (Conrac) vanes on later-generation Boeing platforms, including the 737-600, 737-700, 737-800, 737-900, 747-400, 757, 767, 777, and 787 families. It is also compatible with the Lockheed Martin C130J.
R/C-AOAC-3
The R/C-AOAC-3 is designed for earlier Boeing platforms, covering vanes on the 727, 737-100, 737-200, 737-300, 737-400, 737-500, 747-100, 747-200, and 747-300.
R/C-AOAC-4
The R/C-AOAC-4 is a wide-fit model covering the MD-11, MD-90, and B717 platforms.
R/C-AOAC-2SPSD
For operations in more demanding environments, the R/C-AOAC-2SPSD provides fully enclosed protection against ice, snow, blowing debris, and other severe-duty hazards. It shares the same airframe compatibility as the R/C-AOAC-2 – covering the Boeing 737-600/700/800/900, 747-400, 757, 767, 777, and 787 families – and adds a Nomex® cover with flame-retardant hook-and-loop fasteners for superior thermal and environmental protection, while still allowing full interior access during installation and removal.
The Bottom Line
With six models covering everything from light business jets to wide-body commercial aircraft, Sesame Technologies has a solution for virtually any operator. Pilot John International® (PJi®) carries the full Sesame Technologies angle-of-attack cover lineup, including the new Executive Series models.
Not sure which cover is right for your aircraft? Reach out to our aviation specialists by phone, email, or live chat – we're happy to help you identify the right cover and place your order.
