Abstract <p>This paper presents the design and modeling of a rotating eddy current array (ECA) system tailored for efficient detection and sizing of defects in complex and multilayer aerospace structures. The proposed system integrates a transmit/receive coil configuration with a rotating scanning mechanism, enhancing sensitivity, spatial resolution, and inspection coverage. Detailed descriptions of the sensor architecture, multiplexing strategy, and excitation parameters are provided, along with schematic illustrations of the system design. Simulation results demonstrate the system’s ability to detect defects regardless of rivet size or layer geometry, indicating uniform sensitivity and improved robustness. These findings confirm the system’s potential for reliable and rapid non-destructive evaluation of aerospace components, particularly in geometrically complex environments.</p>