Lufthansa's Sharkskin Coating on Planes Reduces Tons of Emissions – Here's How it Works

A sharkskin inspired modification on aircraft has avoided thousands of metric tons of carbon dioxide emissions, the company behind the technology told Skift.

Lufthansa Technik, the maintenance arm of Lufthansa Group, developed Aeroshark, a special film that mimics the texture of sharkskin to improve airflow and reduce drag. 

Although trial runs began in the late 2010s, commercial use only took off after the Covid-19 pandemic. 

Since then, planes using Aeroshark have logged over 160,000 flight hours, saving 9,800 metric tons of fuel and 31,000 metric tons of CO2 emissions, Lufthansa Technik claims.

In its recent annual report, Lufthansa highlighted Aeroshark and said it “significantly reduces air resistance and lowers fuel consumption and carbon emissions.”

However, aerodynamic improvements are just one small part of the puzzle in trying to reduce aviation emissions.

Currently, the most effective way to reduce emissions in aviation is thought to be more efficient aircraft. 

The International Air Transport Association (IATA) said in a report that newer more efficient aircraft could reduce emissions by up to 25% when compared with older models.  

“Each plane and airline has a different figure and saving depending on the route and loading profiles of their aircraft. But if you look at the absolute figures for example one of our first clients, Lufthansa Cargo, we have an annual saving of 1,170 metric tons of CO2 every year for one aircraft,” said Michael Lagemann, spokesperson for Lufthansa Technik.

“It’s a small contribution but it is an effective one and it’s available only for certain types of aircraft at the moment but we’re trying to expand the portfolio,” he added.

What Is Aeroshark and How Does it Work?

Aeroshark is a film made primarily of plastic and features a ribbed texture with tiny, prism-shaped bumps called riblets that mimic the skin of a shark. Each riblet is about 50 micrometers wide.

Lufthansa Technik said that when applied to an aircraft’s surface, these riblets align with the airflow, reducing friction during flight - just as sharkskin helps a shark move efficiently underwater.

“Currently, the coatings cover around 40% of the plane, mainly large parts of the fuselage. But the more it is applied, the more drag that can be reduced and the more fuel savings and avoided emissions,” Lagemann said.

However, some parts of the aircraft don’t benefit from the coating. “Certain areas already have optimal airflow, so there’s little room for improvement. Other parts, like sensors, need to remain clear of any coatings,” Lagemann added.

What Airlines and Planes Use Aeroshark?

More than six airlines have adopted Aeroshark, including Lufthansa, Lufthansa Cargo, Latam, Swiss, Austrian Airlines, and All Nippon Airways. 

According to Lufthansa Technik, over 25 aircraft now feature the coating.

Swiss, which has modified its entire Boeing 777 fleet of 12, saves CO2 emissions equal to around 87 long-haul flights from Zurich to Mumbai.

Latam has installed Aeroshark on some of its Boeing 777 aircraft and has plans to fit it on four more.

This expansion at Latam could lead to annual savings of 6,000 metric tons of CO2 per year, which is the equivalent to approximately 28 scheduled flights from São Paulo to Miami on a Boeing 777.

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