50,000 flight hours with AeroSHARK

By now, 16 aircraft modified with the drag-reducing riblet film are roaming the skies. The eleven Boeing 777-300ERs of Swiss International Air Lines and four 777F of Lufthansa Cargo have been busy collecting flight hours. Along with Lufthansa’s Boeing 747-400 the squad has already accumulated more than 50,000 flight hours with AeroSHARK. 

As you have noticed, the population of AeroSHARK-modified Boeing 777s is growing. Thanks to the nature-inspired riblet film these aircraft are operating approximately one percent more fuel-efficient. The unique sharkskin technology, jointly developed with BASF, allows the aircraft to glide through the air with less friction, reducing fuel consumption and cutting emissions.

Our AeroSHARK fleet is not just making waves, it’s making real impact:

> 50,000

Flight hours


Metric tons of jet fuel


Metric tons of CO2 savings

*calculation based on aircraft-individual fuel consumption data, including „cost of weight“ factor.

Shrinking your carbon footprint

Cutting emissions with sharkskin technology

Just by using the sharkskin technology, the global fleet of long-haul aircraft could save close to five million tons of kerosene per year. And we are well past proof of concept! AeroSHARK is a durable bionic film that successfully mimics the skin of sharks and optimizes the airflow thus enabling significant fuel savings. 

Together with the leading global chemicals and coatings manufacturer BASF, we developed a functional biomimetic technology: a film with a barely perceptible ribbed texture of small protrusions – riblets. Sized in patches for easy and targeted application, the film has millions of these prism-shaped riblets, each one 50 micrometers high.  Applied to the aircraft in a specific manner and aligned with the airflow, the riblets achieve efficiency gains, by reduced friction, similar to those of their counterparts in nature, and can also improve lift if attached on wings.

The riblet film is easy to apply, even on large commercial aircraft - up to 500 m2 on a Boeing 747-400's lower fuselage and belly fairing. It is extremely resilient, withstands large temperature shifts, pressure differentials and the ultra violet radiation on high flight levels.

Fact is that our riblet technology can be applied to any aircraft with a similar effect

Jens-Uwe Mueller, 

Manager AeroSHARK

More than a cost-effective and scalable solution

Combining BASF's advances in coating technologies and application processes with our extensive experience in aircraft engineering, research and testing resulted in a unique solution. It checks all the key boxes: cost-effectiveness, scalability, retrofittability and sustainability. And the latter not only because of its impact on fuel savings and emissions reduction, but also due to its lower manufacturing and application footprint compared to other technologies. 

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AeroShark @Lufthansa Cargo

Lufthansa Cargo equips freighters

Flying more sustainably

AeroSHARK is to be rolled out on Lufthansa Cargo's entire Boeing 777F freighter fleet from the beginning of 2022, making the aircraft more economical and reducing emissions. Here we estimate a drag reduction of more than one percent. For the entire fleet of ten aircraft, this translates to annual savings of around 3,700 tons of kerosene and just under 11,700 tons of COemissions, which is the equivalent of 48 individual freight flights from Frankfurt to Shanghai. 

We are proud that we will now be able to operate our entire freighter fleet even more efficiently in the future thanks to sharkskin technology and reduce the carbon footprint of our modern fleet further.

Dorothea von Boxberg, 

CEO Lufthansa Cargo AG

No hype. Results.

By late November 2019, it was clear that the riblet film jointly developed with BASF's Coatings Division was delivering on its promise under real-life operating conditions, too.  AVIATAR's Fuel Analytics solution was used to sense any variations in fuel consumption pre and post modification down to 0.8%, accurately accounting for externalities such as weather conditions, flight profile and even minor impacts on the fuselage. Initial results for the 747-400 with a lower fuselage modification showed a 0.8% drag reduction from the effect of AeroSHARK which translates into annual fuel savings of just about 300 metric tons of kerosene. This means a reduction in C0emissions of more than 900 metric tons per year.  

Worker cutting aeroshark riplet

Fully qualified and certified material

Our sharkskin riblet film was tested in laboratory and real flight conditions: 

  • Climate and UV exposure
  • Fluid exposure (such as water, oil, etc)
  • Several adhesion and functionality tests



  • Fuel-savings
  • Emissions reduction
  • Possibility to apply it to any aircraft
  • No additional down-times
  • The riblet film can be easily adapted also to your aircraft. 

Our adoption of AeroSHARK is an excellent example of how we can use innovative technologies to make air travel more sustainable.

Dieter Vranckx

CEO Swiss International Air Lines Ltd.

Watch the video: All about AeroSHARK


AeroSHARK Productinformation

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Jens-Uwe Mueller

Manager AeroSHARK

Lufthansa Technik AG | Hamburg, Germany

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