ReSiSTant · Project

Super-Hard Micro-Grooved Coatings That Cut Drag and Boost Efficiency in Engines and Compressors

manufacturingPilotedTRL 7

Imagine running your hand over a shark's skin — those tiny grooves actually help it glide through water with less resistance. This project applied the same idea to aircraft jet engines and industrial compressors by creating microscopic grooves (called riblets) on their internal surfaces. The tricky part was making these grooves tough enough to survive extreme heat, corrosion, and wear inside real engines. The team added nanoparticles to harden the coating and even built in a self-cleaning feature, then tested everything on an actual CFM56 jet engine.

By the numbers

up to 8%

Drag reduction in turbulent boundary layer using riblet surfaces

Efficiency increase targeted per single compressor stage

less than 5 hours

Target time for new surface manufacturing process

TRL7

Target maturity level for the pilot lines

EUR 5,485,000

Total EU contribution to the project

Consortium partners across 7 countries

The business problem

What needed solving

Aircraft engines and industrial compressors lose significant energy to aerodynamic drag caused by turbulent airflow over internal surfaces. Traditional smooth surfaces offer no drag reduction, and existing coating technologies cannot survive the extreme heat, mechanical stress, and corrosive environments inside these machines. Companies need a surface treatment that cuts friction losses while lasting under real operating conditions.

The solution

What was built

The project built nano-functionalized riblet coatings with super-hardness, temperature resistance, corrosion protection, and self-cleaning properties. They created two industrial pilot lines, assembled dedicated test rigs for both demonstrators (DEM1 and DEM2), and completed tests on a real CFM56-5C turbofan engine. A total of 22 deliverables were produced including a database of experimental data for validation of aero-acoustic and forced response prediction tools.

Audience

Who needs this

Aircraft engine manufacturers (e.g., turbofan and turbine component makers)Aviation MRO providers applying surface treatments during engine overhaulsIndustrial compressor manufacturers and operators in oil & gas or chemical processingSurface coating and treatment companies looking for high-performance product linesAirlines and fleet operators seeking fuel savings through engine efficiency gains

Business applications

Who can put this to work

Aviation MRO and Engine Manufacturing

enterprise

Target: Aircraft engine manufacturers and maintenance providers

If you are an aircraft engine manufacturer or MRO provider dealing with rising fuel costs and tighter emissions regulations — this project developed a nano-functionalized riblet coating for turbofan engines that reduces turbulent drag by up to 8%. The coating was tested on a real CFM56-5C engine and can be applied in less than 5 hours, meaning minimal aircraft downtime during maintenance cycles.

Industrial Gas Compression

mid-size

Target: Compressor manufacturers and operators in oil & gas, chemical processing

If you are an industrial compressor operator struggling with energy costs and efficiency losses — this project built and tested riblet coatings that reduce aerodynamic shear stress inside compressor stages, targeting a 1% efficiency increase per stage. They built two full demonstrator test rigs (DEM1 and DEM2) and completed evaluation testing on both.

Advanced Surface Coatings

SME

Target: Surface treatment and coating companies

If you are a coating company looking to expand into high-performance anti-drag surfaces — this project developed a manufacturing process for nano-functionalized riblet coatings with built-in corrosion protection and self-cleaning properties. The process targets completion in less than 5 hours with high reliability, opening a new product line for aerospace and industrial clients.

Frequently asked

Quick answers

What would it cost to apply this riblet coating to our equipment?

The project does not publish per-unit coating costs. However, the manufacturing process was designed to be completed in less than 5 hours, which suggests manageable labor and equipment time. Contact the coordinator Bionic Surface Technologies GmbH for commercial pricing.

Can this be applied at industrial scale or is it still lab-level?

This is well past lab scale. The project ran two industrial pilot lines — one for aircraft turbofan engines, one for industrial compressors — and tested on a real CFM56-5C engine. With 12 partners across 7 countries and 67% industry participation, the consortium was built for scale-up.

Who owns the IP and can we license this technology?

The coordinator is Bionic Surface Technologies GmbH, an Austrian SME specializing in surface technologies. IP from EU-funded Innovation Actions typically stays with the consortium partners. Licensing discussions should start with the coordinator.

How durable is the coating in harsh operating conditions?

Durability was a core focus. The team used nano-functionalization — embedding nanoparticles into the riblet surface — specifically to achieve super-hardness and resistance to mechanical wear, high temperatures, and corrosion. A self-cleaning mechanism was also built in using nanostructures.

What real-world testing has been done?

Extensive testing was completed. The project applied riblets to two demonstrators (DEM1 and DEM2), assembled and commissioned dedicated test rigs for both, and ran tests on a modified CFM56-5C turbofan engine — a widely used commercial aircraft engine. All 7 demo deliverables confirm completed testing.

Does this meet aviation certification requirements?

The project targeted TRL7 (system prototype demonstration in an operational environment). While the CFM56-5C tests are a strong step, full aviation certification (EASA/FAA) would require additional qualification beyond this project's scope. Based on available project data, certification-readiness is not explicitly confirmed.

Consortium

Who built it

The ReSiSTant consortium is strongly industry-oriented: 8 of 12 partners (67%) are industry players, with 2 SMEs including the coordinator Bionic Surface Technologies GmbH from Austria. The remaining partners — 2 universities and 2 research organizations — provide the scientific backbone. Spread across 7 countries (Austria, Switzerland, Germany, Spain, Israel, Italy, Poland), the consortium covers key European aerospace and manufacturing hubs. With EUR 5.49 million in EU funding and a real CFM56 engine test completed, this is a commercially serious team, not a research exercise. The SME-led coordination signals that business exploitation was a priority from day one.

BIONIC SURFACE TECHNOLOGIES GMBHCoordinator · AT
TECHNISCHE UNIVERSITAET GRAZparticipant · AT
RHEINISCH-WESTFAELISCHE TECHNISCHE HOCHSCHULE AACHENparticipant · DE
LUFTHANSA TECHNIK AKTIENGESELLSCHAFTparticipant · DE
RINA CONSULTING SPAparticipant · IT
MAN DIESEL & TURBO SCHWEIZ AGparticipant · CH
FUNDACION IDONIALparticipant · ES
GE AEROSPACE POLAND SPOLKA Z OGRANICZONA ODPOWIEDZIALNOSCIAthirdparty · PL
GENERAL ELECTRIC DEUTSCHLAND HOLDING GMBHparticipant · DE
RINA CONSULTING - CENTRO SVILUPPO MATERIALI SPAthirdparty · IT

How to reach the team

Bionic Surface Technologies GmbH (Austria) — SME specializing in surface technologies. Reach out via their company website for licensing or partnership inquiries.

Order a report on this consortium See BIONIC SURFACE TECHNOLOGIES GMBH profile →

Next steps

Talk to the team behind this work.

Want to explore how riblet coatings could cut drag and boost efficiency in your engines or compressors? SciTransfer can connect you with the ReSiSTant team and provide a tailored technology brief.

Order a report on this topic More in Manufacturing & Industry 4.0