‘You’re quickly talking about one to two thousand sensors for big traffic bridges’
Villari is lengthening the life cycle of steel bridges and cranes by using smart sensors
Bridges, industrial cranes and other steel constructions must be safe. This is why they are regularly inspected. But the inspections are often still done by hand in places that are hard to reach and by scarce technical personnel. Villari, a TU Delft spin-off, designed smart, wireless sensors that detect crack propagation in steel constructions at an early stage. This gives engineers a continuous picture of the state of critical parts and means that bridges and cranes can sometimes be safely used for many more years. “The high-frequency information enables engineers to do more targeted maintenance, which avoids the unnecessary replacement of intact parts.”
How can you reduce the need to replace infrastructure prematurely?
A lot of bridges and industrial constructions were built in the 1960s or earlier. This means that asset owners are facing growing maintenance jobs. At the same time, there is a shortage of specialized personnel and inspections are becoming more complicated. Given the limited information, the people responsible quickly opt to replace a relatively old bridge or crane for safety reasons.
Villari wants to change this. The company’s sensors are placed at welded seams, the places where cracks often first appear. “Welds are the critical points,” says co-founder Olivier Baas. “That’s where the first cracks happen.”
By monitoring 24/7 and sending warnings about crack propagation automatically, a much more detailed picture can be generated than in the quarterly or half year inspections. Engineers can prioritize the maintenance and take more targeted action.
“A new start-up is too risky for the average investment fund. And it is actually in this phase that you benefit from support, including knowledge.”
Reliable data allows asset owners to better assess if a construction can still be used safely. This avoids the unnecessary replacement of parts that are still intact. Villari thus helps lengthen the lifespan of steel assets and, by extension, reduces the pressure on scarce raw materials.
In doing so, the technology complements a wider movement in infrastructure and industry: the move from reactive or periodic maintenance to data-driven and preventive maintenance.
The step to proof and certification
Developing a promising technology is one challenge. Proving that it is reliable enough to be used for critical infrastructure is another. Certification was therefore an important milestone for Villari.
The company earned the DNV certification that confirms compliance with the technical standards and strength of the solution. Villari also got a patent for its technology for crack detection. These pave the way for further scaling up.
The number of sensors installed has increased significantly. Villari is working for a growing client base that includes European steel companies, port terminals, and critical infrastructure projects in the Benelux. It is also forging partnerships with major players in infrastructure management that can use Villari’s sensors in their regular health monitoring services.
Early support for a risky phase
Through UNIIQ, the proof-of-concept fund, InnovationQuarter was the first investor in Villari in 2022. This is a tricky phase for many start-ups as the technology may be very promising, but traditional investors deem it as too risky.
Olivier says that “UNIIQ is a wonderful tool. A new start-up is too risky for the average investment fund. And this phase is actually where you benefit greatly from support and knowledge.”
One year later, an investment of € 2.5 million was made by InnovationQuarter Capital, FORWARD.one and Delft Enterprises. This allowed Villari to invest in field tests, marketing, sales and expanding the team. In 2025, the company received another € 4 million from FORWARD.one and InnovationQuarter, with the involvement of two individuals who are important for the company.
That new financing came at an important point. Customer demand was growing, the technology was proving itself more and more in practice, and the step to rolling out internationally was coming closer.
Is financing also needed to move from proof to scaling up?
Villari shows how early-stage financing and follow-up investments help to further test a proven technology, get certified, and bring a product to market at a larger scale.
Enter the market from your office
For Villari, the value of InnovationQuarter lay not only in capital. InnovationQuarter also helped move the company forward through access to stock markets and international missions. “This is how they pull you, as a start-up, out of your office,” says Olivier.
This is important, especially for a technology company working in infrastructure and industry. The solution needs to be more than just technically right, it also needs to be visible to asset owners, maintenance partners, and international clients. Growth needs market access, trust and the right network.
What is now possible?
In the time to come, Villari will work on further rolling out in Europe and taking its first steps towards expanding worldwide. The company will simultaneously continue to work on both a stronger product and reducing production costs. After all, to make sensors a standard part of inspections and maintenance, they need to be scalable and affordable.
One or two thousand sensors are needed for large traffic bridges. If they are used at a large scale, it will fundamentally change the way in which bridges, cranes and other steel constructions are managed.
Are you also ready to move from proof to scaling up?
A certified technology is only the start. Scaling up calls for product validation, market entry, financing, and partners that trust your solution. Explore the opportunities to help move your innovation further.
