FlexFoil aims to seamlessly boost airplanes' fuel efficiency

FlexFoil aims to seamlessly boost airplanes' fuel efficiency
FlexSys' variable geometry airfoil, the FlexFoil
FlexSys' variable geometry airfoil, the FlexFoil
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FlexSys' variable geometry airfoil, the FlexFoil
FlexSys' variable geometry airfoil, the FlexFoil

If there's one thing that needs to be aerodynamic, it's an airplane wing. Conventional wing designs however, suffer from a glaring weakness in this respect: the joint where the main wing meets the trailing flaps. Michigan-based FlexSys has developed a way to optimize wing aerodynamics with FlexFoil, a seamless variable geometry airfoil system that could deliver fuel savings of up to 12 percent.

In development since 2001, FlexFoil is made from what is described only as "aerospace materials," and is seamlessly integrated into the trailing edge of the wing. It can be retrofitted into existing wings, or incorporated within new ones.

Based on a technology known as "distributed compliance," the morphing structure integrates actuators and sensors that, according to Flexys, results in "large deformations in shape morphing with very small strains."

According to a 2006 paper co-written by the inventor of the system, mechanical engineer Dr. Sridhar Kota, the foils are "optimized to resist deflection under significant external aerodynamic loading and are just as stiff and strong as a conventional flap."

More precisely, they can reportedly tolerate "well over" 10,000 lb (4,536 kg) in air loads. Additionally, the design is said to distribute pressure more evenly throughout the wing, resulting in less strain in any one area.

When retrofitted onto a wing, FlexFoil can reduce fuel consumption by a claimed 4 to 8 percent, with that number climbing to 12 percent for "clean sheet" builds. The system is also said to reduce wind noise by up to 40 percent on landing, and to lessen build-up of both ice and debris.

What's more, the technology could be applied to anything that moves relative to a fluid medium – that could include things like helicopter rotor blades, wind turbine blades, boat rudders, or pump impellers.

FlexFoil was officially introduced to the public this week at the AIAA (American Institute of Aeronautics and Astronautics) SciTech exposition in Washington, DC. Plans call for flight tests to be performed this July at NASA's Dryden Flight Research Center, where the flaps of a Gulfstream business jet will be replaced with the foils.

A prototype foil can be seen morphing in the video below.

Source: FlexSys

At last, a shape-morphing aircraft wing is here - no flaps

Ryan Gibbons
This Is interesting Technology...
What's old is new again. The Wright brothers used wing warping as a control surface:
This is the same principle.
Bryan Haslett
I sure would like to get a peek at the actual technology. Maybe a computerized cutaway showing the internal geometry?
From the article my limited brain cannot determine what is really going on.
From a rotary wing standpoint it would be fabulous to be able to dynamically tune each rotor for the instantaneous aerodynamic requirements at any given moment. Unfortunately I don't see it being able to morph a rotors shape, let's say, 264 times per minute (approximate rpm of a BlackHawk system). Also, can it withstand the tremendous forces due to the centrifugal loads? Around 40 tons at the blade root!
Even if it was nothing more than the trailing edge flaps used for balancing the whole rotor, it would certainly improve the ability to keep the system tracked and balanced.
It's a shame that as a society we don't learn from the past but I'm glad that in individual disciplines they can and do.
On with the future.
Uh, Takis, did you watch the video? They mentioned the Wright brothers connection right at the beginning. It's not like they're trying to hide it.
Don Duncan
Is the "fixed wing" design now morphing into a "control wing"? I hope so. I have waited for the control wing since I became aware of it in 1995.
Also, the aerodynamics of a car could change as speed changed. But how long will it take the manufactures to contact Flexsys? If I was Flexsys, I would contact them.
Lewis M. Dickens III
Contrary to popular opinion there are still some very intelligent and creative people here in Michigan.
Don't forget Nils Joel Skrubb who created the Packard Merlin by redesigning completely to American Standards a fine design from England. Some say it won the big war.
now if I can get an economy version for my microlight and my prop,,,wow what a concept
This looks like a very viable and safe way to enhance efficiency and speed. The ability to retrofit this FlexSystems to existing aircraft is certainly market appealing on a global scope.
It appears by institutes you have associated yourself with this will "Fly High"...pun intended. I see this creative technology especially valuable initially in the GA, Turbo Prop market as well as business jets. Six (6%) helps a lot and 12% is another game changer. When you couple the FlexSystem Technology with NexGen engines even in the smaller aircraft markets...with some of the new materials and aerodynamic tweaks...20% -23% fuel savings is very possible. Superb Job!
Apparently car aerodynamics would also benefit greatly. I remember seeing (perhaps here) examples of DIY aero retrofits where people closed all the various door, hood, and trunk gaps to achieve noticeably better mileage - of course at the expense of having an easy to open door :) A flexible cover would solve that, at least for the joint sides.
Ian McIntosh
Certainly not novel, they tested these wings on F111s last century. They called it a "Mission Adaptive Wing" then....
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