Aerospace

Lufthansa Technik Uses Ansys to Develop and Certify AeroSHARK Technology

In order to design and certify AeroSHARK, a biomimetic coating technology that mimics shark skin and greatly lowers fuel consumption and carbon dioxide (CO2) emissions, Lufthansa Technik, one of the world’s top providers of technical aircraft services, integrated Ansys simulation systems.

Lufthansa Technik and BASF, a chemical business, created the coating film with a slight ribbed structure made up of tiny elevations known as riblets by utilizing Ansys’ computational fluid dynamics (CFD) and high-performance computing (HPC) technologies.

Lufthansa with aerodynamic sharkskin film(Opens in a new browser tab)

The placoid scales on a shark’s skin, which let them smoothly cut through water by lowering drag and friction while improving buoyancy, are mimicked by the riblet effect. To be sure the riblets’ surrounding turbulent flow phenomena would provide the same effect, engineers employed Ansys’ CFD software.

Before scaling and customizing the AeroSHARK prototypes through extensive aerodynamic simulations, Lufthansa Technik built and validated smaller, more generic virtual prototypes using Ansys’ capabilities. Lufthansa Technik significantly shortened the time it took to obtain certification by being able to simulate the entire aircraft, including in-flight behavior, and verify the Riblet effect using cutting-edge turbulence modeling.

Lufthansa Technik to maintain India’s Vistara Dreamliners in Frankfurt(Opens in a new browser tab)

Swiss International Air Lines (SWISS) and Lufthansa Cargo are now using AeroSHARK, which has been approved for use on two models of Boeing 777s by the European Aviation Safety Agency (EASA) and the American Federal Aviation Authority (FAA). After receiving their AeroSHARK modifications, all eleven Boeing 777Fs at Lufthansa Cargo and all twelve 777-300ERs at SWISS will cut the yearly carbon footprint of the Lufthansa Group by more than 25,000 tonnes.

As a result of successful simulation-powered testing, AeroSHARK is currently able to cover 40% of the aircraft, with plans to eventually expand its coverage to other parts of the aircraft.

Aerospace

Boeing’s Aurora Flight Sciences Expands Columbus Plant by 50,000 Sqft

Credit:Aurora Flight Sciences

Aurora Flight Sciences, a subsidiary of Boeing, has launched a significant expansion of its manufacturing facility near the Golden Triangle Regional Airport in Columbus, Mississippi.

This ambitious project will add 50,000 square feet of new space, renovate 40,000 square feet of the existing facility, and introduce advanced automation equipment, robotics, and non-destructive inspection technologies. mcas boeing enhancements will support the growing demand for Aurora’s aerospace systems business.

Since its establishment, Aurora Mississippi has specialized in the production of advanced composite components and assemblies for both military and commercial aircraft. The company first opened in 2005 at Mississippi State University’s Raspet Flight Research Laboratory in Starkville before relocating to its current site in Columbus two years later.

Initially occupying 21,000 square feet, the facility has since grown to encompass over 120,000 square feet, featuring cutting-edge manufacturing technologies such as automated fiber placement. Aurora’s latest expansion is a strategic investment aimed at increasing production capacity for composite components like boeing titanium used in executive jets and the MQ-25TM Stingray composite skins, a key project for its parent company, Boeing.

Additionally, the facility will produce components for NASA’s X-66 sustainable flight demonstrator aircraft, further diversifying its portfolio. Currently employing around 100 full-time staff in Mississippi, Aurora plans to hire more than 60 additional team members by the end of 2025.

Aurora’s expansion project underscores its commitment to Mississippi’s growing aerospace and advanced manufacturing sector. The company maintains strong partnerships with Mississippi State University (MSU) and East Mississippi Community College (EMCC), contributing to research, higher education, and workforce development in advanced manufacturing.

Additionally, Aurora actively supports local K-12 STEM education through summer camps and collaborates with high school vocational education programs. The expansion and renovation project will be carried out in phases over the next two years, with completion expected by 2026. This development marks a significant milestone in Aurora’s ongoing growth and its role in advancing aerospace manufacturing in Mississippi.