Sesame Technologies Aircraft Pitot Probe Covers
Key Takeaways
- Pitot probes directly affect airspeed accuracy – and unprotected or improperly covered probes have caused real-world emergencies, from insect-blocked sensors forcing emergency landings to melted covers damaging probes during engine start.
- Sesame Technologies' pitot probe covers are made from Kevlar® – nonflammable, high-temperature rated, and safe to leave on during a heat cycle – unlike vinyl or polyester alternatives, which can melt onto and permanently damage the probe.
- All four models (KPC3, KPC4, KPC4T, KPC6) share core features: flame resistance, water repellency, breathability, metal-free construction, NAS-approved warning streamers, and Boeing and Rosemount Aerospace approval.
- The models differ by construction depth, temperature rating, and application: KPC3 is the single-layer entry-level; KPC4 adds triple-layer protection; KPC4T adds silicone tip protection for the highest temperature rating (900°F); and KPC6 features a silicone-molded body optimized for lanyard system use.
- Sesame Technologies' installation tool and lanyard system allow ground-level cover placement and removal, and ensure no covers are left on before flight – addressing the exact scenario that caused the 2018 Malaysia Airlines incident.
Pitot probes are among the most safety-critical sensors on any aircraft. These flow-measurement devices determine airspeed – and when they're damaged, blocked, or left unprotected on the ground, the consequences can be severe.
Sesame Technologies, Inc. produces a line of patented, military-grade pitot probe covers engineered to prevent exactly these scenarios, protecting sensors from heat damage, insect intrusion, contamination, and accidental contact when the aircraft is on the ground.
In this article, we'll explain why pitot probe protection matters, what sets Sesame Technologies covers apart from the competition, and which model is right for your aircraft.
Why Is Pitot Probe Protection So Important?
Pitot probe failures directly affect airspeed accuracy – and inaccurate airspeed data in flight is a serious safety hazard. In November 2013 and again in May 2017, separate incidents resulted in emergency landings due to insect remains blocking the pitot probes and disrupting the aircraft's pitot-static system. Both events may have been preventable with proper ground protection and pre-flight inspection.
Equally dangerous is the opposite scenario: a pitot probe cover left on by mistake. In July 2018, a Malaysia Airlines flight was forced to turn back after a pitot cover – reportedly made of a heat-sensitive material – melted onto the probe during engine start, damaging the sensor. Replacing a pitot probe can cost tens of thousands of dollars and ground an aircraft for days. Using a nonflammable, high-temperature cover eliminates this risk entirely.
Why Choose Sesame Technologies Pitot Probe Covers?
Sesame Technologies sets itself apart through rigorous R&D, high-temperature material science, and a transparent quality program. Here's how their covers compare to the competition:
- Kevlar® construction – vs. marine-grade vinyl, Naugahyde, or polyester materials
- High working temperature – vs. low melting point materials that can damage probes if left on during a heat cycle
- Will not melt and is nonflammable – vs. covers with very low melting points
- Hand or pole installable and removable – vs. hand-only installation
- Breathable – eliminates condensation – vs. non-breathable covers that trap moisture
- Will NOT damage probes if left on during a heat cycle – vs. covers that will
- AS9100 and ISO 9001 compliant quality program – vs. ISO 9000 or no quality program
- One-year product warranty – vs. no advertised warranty
- All materials made in the USA – vs. materials sourced internationally
The cost difference between Sesame Technologies covers and lower-quality alternatives is minimal. The difference in performance – and consequence of failure – is not. A cover that melts onto a probe during a heat cycle can cost far more to remediate than the small premium paid for a Kevlar alternative.
Installation Tools and Lanyard System
To support safe and efficient installation and removal, Sesame Technologies offers a lightweight aluminum installation tool (available in three models: IP100-SP24, IP100-SP28-72, and IP100-SP36) that allows technicians to place and remove covers from the ground without a ladder. The companion lanyard system connects all covers so none are left on the aircraft before flight operations begin.
Sesame Technologies Pitot Probe Cover Models
Four pitot cover models are available: KPC3, KPC4, KPC4T, and KPC6. All four share the following features:
- Kevlar® construction – will not scratch or damage the probe
- Flame-retardant (does not melt) and nonflammable
- Water-repellent with chemical and abrasion resistance
- Metal-free and low-particulate
- Soft, pliable, and breathable
- Orange Kevlar® tape installation loops
- NAS-approved warning streamer with part number identification
- Compatible with military, commercial, and business aircraft
- Approved by leading manufacturers, including Boeing and Rosemount Aerospace
KPC3
Single-layer Kevlar® construction with a working temperature of 800°F and a 5,000-hour life expectancy. The entry-level model in the lineup – reliable protection for operators prioritizing straightforward, proven performance.
KPC4
Triple-layer Kevlar® construction with a working temperature of 850°F and a 7,500-hour life expectancy. The additional layers provide enhanced protection and durability over the KPC3.
KPC4T
Triple-layer Kevlar® construction with internal silicone tip protection – the highest working temperature in the lineup at 900°F. Designed for applications where probe tip protection is a priority. 1,000-hour life expectancy.
KPC6
Triple-layer Kevlar® construction with a silicone-molded body designed for easy lanyard attachment. Working temperature of 850°F and a 7,500-hour life expectancy. Ideal for operations using the Sesame Technologies lanyard system.
The Bottom Line
Pitot probe protection is a straightforward, low-cost safeguard against failures that can ground an aircraft, endanger a crew, or cost tens of thousands of dollars in sensor replacement. Sesame Technologies' Kevlar pitot probe covers are the proven choice – nonflammable, high-temperature rated, breathable, and backed by an AS9100/ISO 9001 quality program.
Pilot John International® (PJi®) is your authorized source for the full Sesame Technologies pitot probe cover lineup, including the KPC3, KPC4, KPC4T, and KPC6, as well as installation tools and lanyard systems. Our aviation specialists are ready to help you identify the right model for your aircraft. Contact us by phone, email, or live chat today!
