Salus AeroNanoSealer is a sol–gel derived nano-engineered surface modification system developed to stabilise flow-exposed structures under aerodynamic and environmental stress.

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Through controlled nano-scale fusion and surface functionalisation during curing, the technology integrates with the substrate to modify surface energy, boundary layer interaction, and pressure behaviour — supporting long-term aerodynamic stability.

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The modification integrates at substrate level and does not add measurable weight or alter structural tolerances.

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Technology Platform

Nano Integration & Surface Functionalisation

AeroNanoSealer utilises controlled nano-scale particle integration during curing to create a stable, substrate-level interface.

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Through nano-scale fusion, the system:​

• Modifies surface free energy

• Reduces micro-roughness variability

• Stabilises boundary layer initiation

• Enhances resistance to UV exposure and environmental degradation

• Reduces reliance on superficial coating adhesion

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This results in aerodynamic surface stabilisation rather than temporary drag reduction treatment.

 

Bernoulli Effect & Boundary Layer Behaviour

Aerodynamic systems operate under pressure differentials described by the Bernoulli principle, where airflow velocity and surface condition directly influence local pressure distribution.

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Minor surface irregularities can:​

• Trigger premature transition from laminar to turbulent flow

• Increase drag coefficient

• Alter lift-to-drag balance

• Disrupt pressure stability

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Through nano-scale surface functionalisation, AeroNanoSealer reduces turbulence initiation points and supports more consistent pressure distribution across flow-exposed surfaces. By stabilising surface energy at the nano-scale, the system mitigates gradual aerodynamic performance drift. The integration occurs within the substrate surface and does not introduce measurable weight.

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Independent Validation & Performance Testing

AeroNanoSealer has undergone independent laboratory evaluation and controlled aerodynamic testing to assess drag behaviour, environmental durability, and long-term surface stability.

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Testing protocols include:​

• FAA wind tunnel validation at the William J. Hughes Technical Center

• Drag coefficient measurement across multiple velocity regimes

• ASTM B117 salt spray corrosion testing

• ASTM F1110

• ASTM F483

• ASTM F519-93 / Type 1c

• ASTM F485

• ASTM F502

• ASTM F484

• ASTM D56

• Boeing D6-17487

• Boeing D6-7127

• Douglas CDS #1

• AMS standards

• Cessna C-400 evaluation

• Citation 5 evaluation

• Bombardier Challenger field trials

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These evaluations assess aerodynamic efficiency, environmental resilience, and surface energy stability under cumulative stress conditions representative of operational deployment.

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Aerodynamic Performance Validation

A wing cross-section was mounted in a controlled wind tunnel environment and drag coefficients were measured at multiple velocities comparing untreated and nano-treated surfaces.

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Results confirmed:​

• Up to ~15% aerodynamic drag reduction under controlled test conditions

• Stabilised boundary layer behaviour

• Reduced turbulence initiation points

 

Full technical documentation is available upon request.

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Operational Maintenance Impact

Field deployments report:​

• Up to 75% reduction in cleaning requirements on treated aircraft surfaces

• Sustained surface smoothness under repeated environmental exposure

 

Maintenance impact varies according to operational environment and contamination load.

 

Operational Case References

Westchester County Police Department – Aviation Unit

​Salus AeroNanoSealer® is deployed on helicopters operated by the Westchester County Police Department Aviation Unit, conducting airborne law enforcement and coastal public safety missions in coordination with the United States Coast Guard.

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Application Context

Marine-exposed helicopter fleet operating under salt, moisture, and variable weather exposure.

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Observed Outcomes:​

• Reduced fouling and grime accumulation

• Reduced aerodynamic drag

• Increased operational speed

• Reduced fuel consumption

• Improved maneuverability

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Performance improvement achieved without measurable weight addition.

 

Business Aviation Fuel Efficiency Validation

Deployment included long-haul business aviation aircraft, including a Bombardier Challenger operating Kansas–California routes.

 

Operational Observations:

• Approximately 2% fuel savings based on recorded fuel usage

• Reported speed improvement

• Reported turbulence reduction

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These empirical findings were subsequently confirmed under FAA wind tunnel testing conditions.

Aerodynamic drag reduction correlates with fuel efficiency gains depending on aircraft type, velocity regime, and operational profile.

 

Formulation Profile

AeroNanoSealer is:​

• Water-based

• Free from VOC emissions

• Free from PFAS compounds

• Non-flammable

• Compatible with aerospace metals, composites, and coated substrates

• Engineered for Arctic, offshore, and high-velocity environments

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