Designed for steel structures that keep industries moving, Villari provides continuous visibility into fatigue and crack growth by monitoring passive magnetic flux leakage and plastic deformation. This enables operators to avoid unplanned downtime, improve inspection accuracy, optimize maintenance planning, and extend the lifetime of critical steel assets with confidence.
Villari is a Dutch technology company based in Delft, The Netherlands, trusted by leading operators across ports, industrial facilities, and infrastructure sectors in over a dozen countries worldwide.
Interview with Olivier Baas, CEO & Founder of Villari.
What are the main areas of activity of the company?
Olivier Baas: Villari’s core activity is providing affordable Structural Health Monitoring (SHM) for steel structures using permanently installed, wireless sensors that detect crack initiation and growth.
TThe system supports four key business outcomes for asset owners and operators:
- Avoiding unplanned downtime
- Optimizing repair and maintenance planning
- Improving inspection accuracy and efficiency
- Extending asset life and confidently delaying capital expenditure
While the technology can be applied to virtually any steel structure, current demand is strongest in ports and terminals, steel manufacturing, infrastructure (such as bridges), and offshore environments.
What’s the news about new products/services?
O.B: In October 2025, Villari announced a partnership with MISTRAS Group (a global asset integrity & testing company) to integrate Villari’s wireless crack-detection sensors into MISTRAS’s monitoring solutions. MISTRAS Group, Inc. This partnership announcement has been the most significant until now, however, during Sept and Oct we announced some other partnerships with local experts like Tordis Plus in Turkey, or Dubai Cranes in the Middle East.
A new version of the hardware was released (the Ferro One sensor as it was named) to improve our crack detection capabilities with some improved features in terms of lifetime, temperature tolerance, and size of detection area per sensor among others Link to the post.
Earlier (January 2025) we raised an investment of €4 million to fuel expansion. Innovationquarter
What are the ranges of products/services?
O.B: Villari offers a globally deployable, DNV approved monitoring system consisting of three integrated components:
- Wireless sensors: permanently installed sensors with a 5yr + battery life, withstanding a wide range of temperature difference (-40°C to +80°C, allowing easy installation & configuration without any special surface preparation required
- Intelligent algorithms: based on magnetic field response variations tailored to the specific configuration required by the customer we detect crack and plastic deformation growth with the highest accuracy
- Real-time insights dashboard: where we convert data into intuitive insights and a system that can be integrated into the existing IT infrastructure of the customer.
Villari delivers this as a full-service solution, including installation (by Villari or certified partners), data handling, interpretation, and asset health reporting.
What is the state of the market where you are currently active?
O.B: The market for condition monitoring of steel infrastructure is growing rapidly, driven by aging assets, increasing safety requirements, and the need to maintain availability without excessive downtime.
In sectors like ports and terminals, downtime, inspection costs, and access challenges remain significant pain points. While many operators still rely on traditional calendar-based inspections, this creates strong potential for continuous monitoring solutions that complement existing inspection regimes.
Villari occupies a unique position by offering magnetic-based crack detection that works alongside established NDT methods rather than replacing them.
What can you tell us about market trends?
O.B: Key market trends include:
- Aging infrastructure requiring life-extension rather than replacement
- Growing demand for non-invasive, continuously installed monitoring systems
- Increased focus on safety, sustainability, and cost efficiency
- A shift toward data-driven asset management and condition-based maintenance
- Greater collaboration between sensor technology providers and established inspection and integrity service companies
These trends are accelerating adoption of continuous monitoring as a standard layer in asset integrity strategies.
What are the most innovative products/services marketed?
O.B: Villari’s wireless crack-detection system stands out by enabling continuous monitoring of fatigue crack initiation and growth while assets remain fully operational.
Field results demonstrated by customers include:
- Up to 80% reduction in inspection costs
- Safe asset life extension of 4+ years
- 100+ hours saved by reducing manual inspections
- Up to 75% reduction in unexpected downtime
- Return on investment within the first months
What estimations do you have for the end of 2025?
O.B:
- Increase in installed base: signing off and completing a relevant amount of projects thanks to the increasing pipeline and recent partnerships
- Further geographical expansion in the installed base: beyond Europe, likely into North America and Asia through partnerships
- Market penetration: further penetrating key verticals like ports/terminals
- Expanding to new verticals: getting more client conversations going in the wind/energy and offshore sectors
- Announcing more partnerships: we’ve or are about the finalize a few more partnerships before the end of the year.
