Hero – described as a semi autonomous ground vehicle – is a Warton-based project which has been working with the UK Border Agency as they crackdown on the problem.
The brains behind the miniature marvel are from the same team which brought the world the Herti aircraft, which has been used on missions in Iraq and Afghanistan.
The trials will see the
machines help with the physically demanding tasks of searching the undersides of vehicles.
Born out of a concept to help protect British troops on foot patrol in Iraq and Afghanistan, Hero is roughly the size of a briefcase with a wheel at each corner.
Equipped with lights and cameras the vehicle has been checking beneath lorries, coaches and trailers arriving at Calais – Europe's busiest port.
Richard Williams, civil autonomous systems director for BAE, said: "These people will use any means to get past the immigration checks, and catching them can be very hazardous.
"It's a backbreaking, dirty and dangerous job to look under every truck and with 10,000 vehicles each week boarding ferries, it would be impossible to check them all."
Up to 10,000 heavy goods vehicles a week go through Calais, and the crossing attracts many who will risk their lives to get to Britain.
Mr Williams added: "Our work with the Border Agency is just one example of BAE Systems working with potential customers to explore possible uses for new technologies to meet emerging requirements in a civilian environment."
Andy Cole, from the UK Border Agency, said: "Searching for illegal immigrants is a significant part of border control work that is both physically demanding and manpower intensive. We recognise this, and are looking at new ways of working – and new technologies that can be used in the fight against illegal activity.
"The trials have given us a hands-on demonstration of its capabilities and potential of how autonomous and semi-autonomous
technology can free up manpower from dirty and dangerous activities."