Nanosecond Laser Etching for Drag Reduction on Small Aircraft Surfaces: Advances, Challenges, and Future Directions

As fuel efficiency and operational costs become critical concerns in the growing general aviation sector, drag reduction technologies for small aircraft have gained paramount importance. This review critically examines the current state of nanosecond laser etching technology for microgroove-based drag reduction on aircraft skin materials. We synthesize advancements in numerical simulations and experimental approaches while addressing key challenges such as precision control of micrometer-level morphology, thermal-induced microcracks, and material fatigue. A multidisciplinary framework integrating multi-physics modeling and fatigue life prediction is proposed to bridge the gap between laboratory research and industrial implementation. Our analysis highlights that optimized microgrooves can reduce aerodynamic drag in controlled experiments, yet scalability and long-term durability remain critical barriers. This work provides actionable insights for advancing nanosecond laser etching toward certification-ready solutions in small aircraft manufacturing.