Iowa State University’s pulsed eddy‐current system has been redesigned to be smaller, more sturdy and easier to install and operate. Improvements have been made to the electronic circuits, the computer interface, the enclosure design and to the software. Changes have resulted in a much more user‐friendly system that it portable and can be installed quickly and easily in the field. As part of an evaluation of the new system, bond‐thickness measurements on specimens supplied by Cessna were carried out. Results were found to be in good agreement with those obtained by direct measurement. Additional experiments were carried out on corrosion specimens from SAIC Ultra Image Inc. Using data from these specimens a calibration‐based approach to flaw quantification is demonstrated. © 2003 American Institute of Physics