This study showcases the feasibility of a high-throughput, fully automated femtosecond micromachining workstation designed specifically for fabricating riblet microstructures on aircraft engine blades. These riblet patterns are inspired by natural structures and have been shown to reduce aerodynamic drag. The primary objective of this innovative workstation is to enhance the surface texture of engine blades in order to minimize drag forces during flight. By reducing drag, this technology contributes directly to lowering fuel consumption, which in turn results in substantial cost savings for airline operators and a marked reduction in carbon emissions. This aligns with broader industry efforts toward improving energy efficiency and promoting environmental sustainability in the aviation sector.

To enable efficient, high-speed production, the laser processing strategy has been carefully optimized through the use of an advanced optical module. This module ensures highly precise beam shaping and beam splitting, allowing the femtosecond laser to perform consistent, high-resolution structuring across complex geometries. The intricate 3D shapes of the engine blades are managed using a sophisticated closed-loop measurement system. This system continuously evaluates each part’s geometry and automatically adjusts the laser parameters to compensate for variations, tolerances, and potential defects.

Additionally, the system supports intelligent part handling, including flipping components to enable riblet patterning on both sides of the blades. Flow simulations have also been conducted to evaluate the aerodynamic performance of the micromachined riblets, confirming their potential in significantly reducing drag and improving fuel efficiency.