The EU Commission is investing €5.6 million ($6.5 million) into a laser system that creates multifunctional films surfaces inspired by smooth shark skin to reduce drag and ice formation on airplanes or ships — significantly reducing carbon emissions and lowering fuel consumption. Backed by the Photonics Partnership, the project will enable the creation of precise multifunctional patterns from nano- to microscale on polymer films Partners on the project OPTIMAL are developing mastering technology to structure polymer films, fundamentally changing how surfaces interact with air or water, and offering a durable solution that outperforms current smooth coatings. Mimicking the texture of sharkskin, these microstructures, called riblets, are tiny parallel gooves, often just tens of microns deep, that guide the flow of air or water more smoothly over a surface, helping to reduce drag. Microstructures such as riblets could have various functionalities like drag reduction, anti-icing or anti-soiling, but currently, the combination of these functionalities can only be obtained on a laboratory scale. The OPTIMAL project focuses on refining the manufacturing of ‘masters’ — the finely detailed molds or templates from which high-performance surfaces are replicated. By integrating multiple laser lithography techniques, quality monitoring systems, and intelligent control algorithms into a single, streamlined platform, the project is enabling the creation of larger, more complex, and more precise master structures. “We are adding extra value by redefining the way advanced manufacturing processes create these surfaces," said project coordinator Markus Postl. "OPTIMAL has an all-in-one approach: We are bringing together every step of production under one roof.” By integrating laser structuring, quality monitoring, and component production into a seamless workflow, the team is eliminating the need for external treatments or off-site processes, streamlining production and reducing delays. Along with shark skin films, the OPTIMAL team is tackling inefficiencies in existing manufacturing methods by aiming to improve sustainability across a range of applications. Conventional laser structuring tools, such as laser interference lithography systems or direct laser writing, often require time-consuming and, therefore, expensive pre-processing for adjustment and calibration or can only create small, shallow structures, which limits their effectiveness compared to OPTIMAL technology. “By integrating advanced laser technologies with AI and inline quality control, the OPTIMAL project is paving the way for a new era of sustainable industrial manufacturing,” said Elena Turco from Joanneum Research (JOR) and Project Manager at OPTIMAL. “Being able to create precise, tiny structures, the OPTIMAL laser can be used to create tools used in high-tech manufacturing, such as molds for lenses, chips, and multifunctional surfaces. We are making them faster and at a larger scale, which is set to boost efficiency across multiple industries.” According to Turco, the system could improve lenses for clearer visuals and more efficiently manufacturing proccesses. Virtual reality lenses, for example, could be made smaller and cheaper. Areas like photography and eyewear could also see benefits, Turco said. The medical sector could also benefit from the OPTIMAL system, which is being designed to enhance the production of microfluidic chips for Lab-on-Chip devices — small devices crucial for disease diagnostics and chemical analysis. By enabling faster production at lower costs, these life-saving tools could become more affordable and accessible to healthcare providers worldwide. The OPTIMAL project is set to conclude in 2026 and brings together a consortium of European and international partners. These include JOANNEUM RESEARCH and Sony DADC Europe in Austria, micro resist Technology GmbH and BASF Coatings in Germany, DeltaPix APS in Denmark, Università degli Studi di Parma in Italy, University of Zilina and Centrum Vedecko Technickych Informacii Slovenskej Republiky in Slovakia, and HyperVision Ltd. in Israel.
