Lufthansa Technik Trials New-Generation AeroShark Film

Lufthansa Technik has begun trials of an updated form of its AeroShark fuel-saving aircraft coating, with its installation on a Lufthansa City Airlines Airbus A319.

AeroShark is a transparent film with microscopic grooves, or riblets, aligned with the direction of the airflow, which lessens aerodynamic resistance. Initial use of the material has led to reduced fuel burn—and consequently, reduced CO₂ emissions—of around 1%.

The current AeroShark film is restricted to fuselage and nacelles. The new film is more robust, to withstand the higher aerodynamic loads on the wing and tail

With the new trials, various AeroShark material samples are being evaluated, differing in terms of their material and layer composition. The goal of the study is to identify the material that combines the highest durability with easy application, straightforward cleaning, and residue-free removal.

If the upgraded material proves effective, the long-term goal is to use it more widely, both on different aircraft types and on different parts of the airframe—notably the wings, horizontal and vertical stabilizers.

Lufthansa Technik, together with its development partner Surventis (formerly BASF Coatings), will test approximately 70 transparent film patches measuring 20 cm by 20 cm (8 in. by 8 in.) each on the A319 through February 2027.

The patches are attached to selected areas on the sides of the fuselage, together with the inside and outside of the engine cowlings. Their performance will be analyzed over the next few months during regular flight operations between Munich and Hamburg and is expected to provide insights for the further development of the AeroShark technology.

Lufthansa Technik will conduct regular material inspections during the aircraft’s scheduled ground time in Hamburg.

For passengers aboard the Lufthansa City Airlines trial A319, the material will be virtually invisible, being transparent and hardly noticeable to the eye. Flight operations also remain unchanged. For information purposes, a welcome panel featuring the AeroShark design at the aircraft’s entrance draws the attention of interested travelers to the test.

As of July, the Lufthansa Group has equipped 22 aircraft with AeroShark: Swiss’s fleet of 12 Boeing 777-300ERs, Lufthansa Cargo’s five 777Fs, Austrian Airlines’ four 777-200ERs, and one Lufthansa 747-400. As a result, says Lufthansa Technik, the combined fleet saves 19 metric tons of fuel and 60 metric tons of CO₂ daily.

AeroShark is gaining traction across the industry, Lufthansa Technik notes; airlines outside the Lufthansa Group are also using the film to increase the fuel efficiency of their long-haul aircraft.