Current Projects
LOTUS PTO
Full title of the project:
LOTUS PTO – Laser-Structured Bio-Inspired Surfaces for Enhanced Survivability and Efficiency of Marine Power Take-Off Systems
Program:
Clean Energy Transition Partnership (CETP) 2024 – TRI2 Advanced Renewable Energy Technologies for Power Production (Ocean Energy)
Project partners:
International transnational consortium (Austria and partner countries within CETP framework)
About:
LOTUS PTO develops and validates bio-inspired, laser-structured surface technologies to enhance efficiency, durability and survivability of critical components in wave and tidal energy converters, with a specific focus on Power Take-Off (PTO) systems.
Inspired by hierarchical natural surface structures, the project designs and manufactures micro- and nano-structured textures that simultaneously reduce biofouling, improve tribological performance and minimize friction losses in harsh marine environments. By combining advanced laser structuring, high-fidelity simulations, AI-supported microscopy and experimental validation, LOTUS PTO advances the technology from TRL3 (proof of concept) to TRL5 (validation in relevant ocean environments).
Marine renewable energy systems face severe operational challenges due to biofouling, corrosion, wear and fluctuating hydrodynamic loads. LOTUS PTO addresses these limitations through optimized surface architectures that enhance reliability while reducing maintenance frequency and operational expenditure. The methodology integrates interdisciplinary expertise in fluid dynamics, surface engineering, material science and ocean testing to ensure robust upscaling toward real-world conditions.
The project contributes directly to the clean energy transition by increasing efficiency and lifetime of tidal and wave energy systems. Through improved antifouling behavior and friction reduction, LOTUS PTO supports higher device availability, lower lifecycle costs and enhanced performance of ocean renewable energy technologies.
By bridging nature-inspired design, precision laser manufacturing and data-driven optimization, LOTUS PTO establishes a scalable surface engineering platform for next-generation marine energy applications.
ACE WIND
Full title of the project:
ACE WIND – Aerodynamic and Computational Enhancement for Wind Energy Innovation and Drag Reduction
Program:
FFG Basisprogramm – Internationale Kooperation (EUREKA Globalstars Austria–Japan)
Project partners:
Bionic Surface Technologies GmbH (Austria) | LEBO Co., Ltd. (Japan) | NIKON Corporation (associated partner)
About:
ACE WIND develops a next-generation prediction and optimization tool to unlock the full aerodynamic potential of bio-inspired riblet surfaces on wind turbine blades under real dynamic operating conditions. While current wind turbine design and riblet layouts are based on steady-state flow assumptions and 10-minute SCADA averages, real turbines operate in highly dynamic, turbulent environments characterized by rapid wind fluctuations and dynamic stall behavior.
The project investigates the interaction between riblet microstructures, leading-edge roughness and dynamic flow effects to precisely quantify their impact on energy yield. By combining high-fidelity CFD simulations, wind tunnel testing under dynamic stall conditions, field data from operational turbines and reduced-order modeling, ACE WIND will generate a validated forecast tool capable of predicting static and dynamic riblet effects over the full turbine lifecycle.
Current riblet-based forecasts typically guarantee 1–2% additional power output due to static flow assumptions. ACE WIND aims to increase the reliable and guaranteed performance gain to 3–7% by integrating dynamic stall behavior, surface aging and leading-edge roughness into the simulation process. The resulting ACE WIND tool will enable wind farm operators to calculate site-specific energy yield improvements, optimize riblet layouts and develop robust business cases with significantly reduced simulation costs.
By providing accurate, lifecycle-aware performance forecasts, ACE WIND establishes the foundation for scalable riblet deployment in the global wind energy market. The project strengthens Austrian–Japanese technological cooperation and supports the transition toward higher-efficiency renewable energy systems through digitally optimized, bio-inspired surface engineering.
BellyRibs
Full title of the project:
BellyRibs – Drag Reduction and Mission Endurance Enhancement of Military Transport Aircraft through Laser-Processed Riblet Protection Tapes
Program:
KIRAS 2024-2 – Innovation AKUT (Protection of Critical Infrastructure)
Project partners:
Bionic Surface Technologies GmbH | Austrian Armed Forces (Österreichisches Bundesheer)
About:
BellyRibs investigates the transfer of biomimetic riblet surface technology to military transport aircraft in order to enhance operational endurance and efficiency in missions related to the protection of critical infrastructure. The project combines Computational Fluid Dynamics (CFD), precision laser processing and experimental validation to integrate riblet microstructures into certified 3M Belly Protection Tape used on C-130 aircraft.
Riblets – microscopic, flow-aligned surface structures inspired by shark skin – are known to reduce aerodynamic friction by up to 8% under laboratory conditions. In BellyRibs, this effect is translated into a mission-relevant configuration for C-130 and future C-390 platforms. By laser-structuring existing protective tape, the project merges mechanical belly protection with aerodynamic drag reduction in a single, field-compatible solution.
The expected aircraft-level benefit is a fuel reduction of approximately 0.7–1%, corresponding to a measurable increase in range and time-on-station of 1–2%. For ISR-configured C-390 platforms equipped with Litening 5 pods, this directly enhances surveillance duration and operational resilience during infrastructure protection missions.
The project follows a lean, 12-month development cycle including:
CFD optimisation of riblet layouts for C-130 and C-390
Laser structuring of certified protection tape
Experimental validation at BST’s Pipe Test Bench
Practical demonstration via partial mockup application
By validating a dual-function surface system under operationally relevant conditions, BellyRibs strengthens Austria’s technological sovereignty in flow-optimised surfaces while contributing to increased resilience, reduced fuel consumption and improved crisis response capability.
GreenFlow
Full title of the project:
GreenFlow – Energy Efficiency Enhancement of Hydropower Plants through Biomimetic Riblet Surface Technologies
Program:
Energieforschung 2024 – Produktion der Zukunft, FFG
Project partners:
Bionic Surface Technologies GmbH | Universität für Bodenkultur Wien (BOKU) | Global Hydro Energy GmbH | Kelag | JOANNEUM RESEARCH MATERIALS
About:
GreenFlow develops an innovative retrofit solution for existing hydropower plants by integrating biomimetic riblet microstructures with abrasion-resistant and biofouling-reducing coating systems. Inspired by shark skin, riblet structures reduce wall shear stress and friction losses in water-conducting components such as headrace channels, pressure pipes and turbine elements.
The project combines advanced Computational Fluid Dynamics (CFD), large-area micro-structuring technologies (roll-to-roll and step-&-repeat processes), plasma-based surface activation and durable protective coatings to achieve a measurable reduction in hydraulic losses. Targeted performance improvements include a friction reduction of 8–12 %, resulting in an overall efficiency increase of 2–5 % in existing hydropower systems.
In addition to hydrodynamic optimization, GreenFlow integrates biozidfreie, biomimetic anti-fouling concepts and highly abrasion-resistant coatings to ensure long-term performance stability under sediment-loaded flow conditions. The developed technologies are designed for rapid retrofitting without major structural modifications, enabling amortization periods below three years.
By increasing annual energy production while reducing maintenance requirements and CO₂ emissions, GreenFlow contributes directly to climate-neutral energy generation and strengthens the competitiveness of sustainable hydropower infrastructure.
Bilasurf
Full project title: Bio-Inspired Laser Functionalisation of complex 3D Industrial Surfaces
Program: Horizon Europe
Partners: Aimen | Fraunhofer IWU | Fusion Bionic GmbH | Supergrid Institute | Global Hydro Energy GmbH | Ziehl-Abegg SE | Altechna R&D | Southern European Cluster in Photonics & Optics Association
Project webpage: www.bilasurf.com
Information: BILASURF aims at developing and integrating a process for high-rate laser functionalization of complex 3D surfaces using tailored designed bio inspired riblets to reduce friction and improve the environmental footprint of industrial parts | assuring a high throughput with the help of inline monitoring capabilities.
Concluded Projects
Publications
Leitl, P., Flanschger, A., Rodriguez, A., Andergassen, A. (2024)
"Numerical investigation of the impact of different Riblet angles and their effect on drag reduction"
Conference: AIAA Aviation Forum And Ascend 2024
https://doi.org/10.2514/6.2024-3510
Leitl, P., Garcia de Albéniz, M., Flanschger, A., Robinson, G., Bogue, D. (2024)
"Numerical and experimental investigation of different Riblet layouts and their effect on the engine of a Stratos 716 X Business Jet"
Conference: AIAA Aviation Forum And Ascend 2024
https://doi.org/10.2514/6.2024-3509
Leitl, P., Flanschger, A., Reschenhofer, B., Gruber, R., Kurzthaler, M., Fleder, S., Lenartz, M., Neff, F., Hertz, C. (2024)
"Design and testing of Riblet film on a high-performance axial fan stage"
Conference: AIAA SciTech 2024 Forum
https://doi.org/10.2514/6.2024-1111
Garcia de Albéniz, M., Leitl, P., Flanschger, A. (2023)
"Numerical and experimental investigation of Riblet-Coating impact on centrifugal compressor stage performance"
Conference: ASME Turbo Expo 2023
https://doi.org/10.1115/GT2023-103040
Bilinsky, H.C., Quinn, M., McGrath, D., Whitelock, J., Poudyal, S., Bell, D., Leitl, P., Benauer, R., Feichtinger, Ch. (2023)
"Materials and Performance Testing of DCM Drag-Reducing Riblets for Aviation"
Conference: AIAA SCITECH 2023 Forum
http://dx.doi.org/10.2514/6.2023-1762
Flanschger, A., Heinzelmann, R., Messner, M. (2023)
„Between consultation and control: how incubators perform a governance function for entrepreneurial firms”
Accounting, Auditing & Accountability Journal. Vol. 36, 9, 86 – 107
https://www.emerald.com/insight/content/doi/10.1108/AAAJ-09-2020-4950/full/html
Kohl, D., Tsuchihashi,H., Gruber, R., Pichler, K., Goto, Y., Garcia de Albeniz, M., Naito, K., Flanschger, A., Ichinose, G. (2023)
"Numerical and experimental investigation of Riblet application on a helicopter rotor blade"
Conference: AIAA SCITECH 2023 Forum
https://doi.org/10.2514/6.2023-1765
Leitl, P., Feichtinger, Ch., Schatzdorfer, G., Flanschger, A. (2023)
"Numerical study of riblet defects and their impact on performance"
https://doi.org/2514/6.2023-1764
Leitl, P., Garcia de Albéniz, M., Smoker, J., Flanschger, A. (2023)
"Numerical and experimental investigation of different Riblet layouts on a Stratos 716 X business jet"
Conference: AIAA SCITECH 2023 Forum
https://doi.org/10.2514/6.2023-1952
