The KasperAero
Chip Detector

Using ground breaking NZMS technology, the KasperAero Chip Detector product family offers tremendous value, high reliability, and repeatability unlike any other sensor on the market.

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Meeting Industry Needs for Reliable Debris Detection

Ferrous debris plagues mechanical lubrication and fuel systems. Traditionally, it has been difficult to detect and was only monitored in critical, high-reliability applications. There has long been a need for a cost-effective, rugged, ultra-reliable, and highly sensitive ferrous debris sensor.

To meet this demand, KasperAero has invented a new sensor category: the Null Zone Magnetic Sensor (NZMS). This patent-pending design enables the creation of an exceptionally elegant and sensitive debris sensor. Its unique magnetic configuration allows detection of even the smallest ferrous particles without sacrificing durability or reliability. At its highest sensitivity, NZMS technology redefines the role of debris sensors across a wide range of applications.

Industrial Debris Sensors

Off The Shelf Problem Solving

KasperAero offers a range of off-the-shelf industrial debris sensors that are ready for immediate deployment. Built with modular mounting options, they can be easily adapted to multiple port sizes, making integration straightforward across different equipment setups. Our sensors are designed to work seamlessly with common industrial interfaces, including 0–10 V, 4–20 mA, and CAN bus, ensuring compatibility with most monitoring and control systems. This combination of plug-and-play readiness, adaptable hardware, and industry-standard outputs makes them a reliable choice for a wide variety of industrial applications.

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Custom Debris Sensor Solutions

Customized Debris Detection

Our mass-market debris sensor solutions are fully customizable to meet each customer’s unique requirements. They can be configured with either flanged or threaded attachments, and built to withstand any specified temperature and pressure range. Housing materials are available in both durable plastics and robust metals, with O-ring selections tailored to the application’s needs. Even the electrical interface is fully customizable, with either an analog or digital output as desired. Designed for the most demanding environments and optimized for large-scale production, these sensors deliver exceptional performance at highly competitive costs.

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Designed for Precision. Built for Scale.

Engineered for Mass Market Production

Sensors starting at just $35. Final cost varies with configuration and quantity.

Indiscriminate Operation

Whether the collected debris is a single large chip or an accumulation of ferrous dust, operation is reliable and repeatable.

Ultra High Sensitivity

At the most sensitive, KasperAero NZMS Debris Detectors are capable of sensing 0.005 grams of 10-micron ferrous debris.

Adaptable By Design

For higher capture efficiencies, magnet strength can be increased to suit the application requirements with no effect on sensor operation.

Product Features:

Senses Fine Ferrous Dust
High Resolution Analog Output
Extremely Compact
Low Cost
Low Power Draw
Low Noise (EMI/EMR)
Rugged design for harsh environments
No Moving Parts
No Calibration
No Electrodes Exposed to Fluid Environment

Core Capabilities

Continuous ferrous debris detection
Real-time oil condition monitoring
Compact form factor for embedded systems
Rugged design for harsh environments
Zero-maintenance solid-state construction

Strategic Benefits

Prevent unplanned downtime
Lower total cost of ownership
Enable predictive maintenance

Industries We Serve

Industrial Aerospace Automotive Trucking Maritime Defense Heavy Equipment High Uptime Industrial Machinery Wind Turbines Railways

Exceptional Dynamic Range

From micrograms to grams — a single sensor, no saturation.

Detection threshold: ~1 mg | Upper limit: >67,000 mg

Minimum Detectable Target

0.026″ Alloy Steel Ball: ~1 mg

In laboratory conditions, the NZMS detected a single 0.026″ alloy steel ball bearing weighing approximately 1 mg, smaller than a grain of table salt. The sensor's logarithmic output keeps it highly sensitive at the low end, resolving the fine ferrous dust and small particles that indicate the earliest stages of normal wear.

No Saturation at Scale

1.00″ Steel Ball: ~67,000 mg

At the opposite extreme, the same sensor produced a clear, unsaturated output for a 1.00″ alloy steel ball weighing approximately 67,000 mg. The integrated magnet is strong enough to hold the ball in place on its own. The logarithmic response compresses large signals rather than clipping them, extending the sensor's range well into the territory of catastrophic damage events.

67,000:1 Mass Dynamic Range

The logarithmic output of the NZMS is sensitive to fine particles at the low end while remaining unsaturated at the high end. This allows the end user to distinguish between normal wear, extensive wear, and catastrophic damage using a single, continuous output with no range switching and no additional sensor heads required.

The Language of Detection

The industry hasn't settled on a terminology. The following are all synonyms:

Magnetic Chip Detector (MCD)
Electronic Chip Detector (ECD)
Ferrous Debris Sensor
Wear Debris Sensor
Contamination Sensor
Particle Sensor
Foreign Object Detector
Condition Monitoring Sensor

While these names vary, they all point to the same class of devices. But here’s what no one has ever called them:
Metal Dust Detectors (MDD).

Because until now, no sensor has been capable of detecting micron-sized ferrous dust. Now, with our breakthrough Metal Dust Detector (MDD), you can catch the earliest signs of wear before even the smallest particles do damage.

The Language of Detection

The industry hasn't settled on a terminology. The following are all synonyms:

Magnetic Chip Detector (MCD)
Electronic Chip Detector (ECD)
Ferrous Debris Sensor
Wear Debris Sensor
Contamination Sensor
Particle Sensor
Foreign Object Detector
Condition Monitoring Sensor

While these names vary, they all point to the same class of devices. But here’s what no one has ever called them:
Metal Dust Detectors (MDD).

Notice: All technical explanation of the NZMS has been removed from KasperAero.com until patent approval. Documents will be available upon request after signing a non-disclosure agreement (NDA). To access the entirety of our technical documentation, please email Info@KasperAero.com.