Unlike traditional wet-adhesives, dry adhesives are bioinspired solid polymers that owe their adhesion to hierarchical structures. Gecko’s are the most recognizable living creatures relying on this concept to climb walls. A close look at the gecko’s fingers reveals a hierarchical system of micro-and nanoscale filaments. These ensure excellent adaptability and contact to (rough) surfaces and the formation of a large amount of close-range van der Waals surface interactions. The reversible nature of these bonds allows for reversible and repeatable adhesion. This hierarchical system has been identified as the main reason for dry adhesion and has been object of intense research to manufacture man-made solid adhesives. Despite the many efforts, there are some unclear aspects resulting from contradictory scientific reports and a strong focus on a particular polymer chemistry used to make the hierarchical structures. This has left the effects of the material choice on dry adhesion largely neglected. In this research project, we aimed to shed some light on the role of different polymer architecture features on dry adhesion. Most available research has focused on the use of commercial siloxane elastomers that offer almost no control on the polymer synthesis. Instead, we opted to use thermoplastic polyurethane chemistry due to the large versatility this chemistry offers in terms of modification of relevant polymer architecture features. In the absence of available works on thermoplastics a new manufacturing process of such hierarchical structures had to be developed relying on heating, pressure and vacuum to respectively melt the polymer, overcome the high viscosity and impede oxidation. We studied the effects of the polymer architecture and properties on adhesion using a single micropillar architecture and varying the chemical composition (polyol length, aromatic content, hard/soft block ratio), the testing temperature and the pull-off speed. As to the polymer architecture, the best results were found with a short polyol and the lowest hard block fraction that still guaranteed structural integrity. Next to that, it was found that having aromatic rings in the hard segments was crucial, likely due to its beneficial effect on nanophase separation. With those compositions, values exceeding those of state-of-the-art dry adhesives were found, with a maximum of 440 kPa at the Tg and high retraction speeds. Furthermore, we show that while existing models are valid for thermoplastic polyurethanes well below their Tg, once they exhibit viscoelastic behaviour, the loss factor is a much more reliable indicator of performance than the reported stiffness. The effect of the surface energy was also evident but minimal compared to the mechanical properties of the polymers.

The AerGo is a recreational ultralight water-aircraft, designed to be transportable by bike and operated without a license. This report outlines its concept, characteristics, and feasibility.

The AerGo features a biwing design with swept wings, closed by vertical plates at the tips. It has a constant wing chord of 0.79 m and a wingspan of 12 m. The aircraft is powered by two six-bladed propellers mounted on the top wing and driven by electric engines. The lower wing is attached to a buoyant hull, stabilized by side floats. A paddle is used for taxiing and docking on water, as the aircraft is designed exclusively for water take-off and landing. The pilot sits inside the hull and controls pitch by shifting weight on a swing. Roll control is achieved through wing warping, and yaw by rudders. The total empty mass is 44.7 kg. A multipurpose trailer system facilitates storage, transport, and deployment. The AerGo is designed for single-person assembly and operation and is safe to fly for over 270 days per year.

A market analysis of ultralight aircraft reveals a European fleet of over 25,000, with 500 in the Netherlands. While most ultralights are custom-built, successful models like the Woopyfly and Lazair have seen large-scale production. The AerGo’s mobility, ease of use, and hydrodynamic capabilities position it competitively. A conservative estimate projects annual sales of 20 units, with 25% for the Dutch market and 75% for Europe. Expansion to North America is a future opportunity.

The design is driven by weight and energy efficiency, with batteries forming a significant part of the empty weight. The primary energy requirement comes from cruise flight, optimized through airfoil selection. The NACA 6415 airfoil, chosen for its high lift coefficient at zero angle of attack, minimizes drag and maximizes cruise efficiency. The hydrodynamic model, based on DSDS data, estimates a take-off speed of 9.9 kg and a 170 m take-off distance. The computed climb rate is 1.43 m/s, reaching a cruise altitude of 150 m in 105 seconds.

The engine and battery design prioritize take-off power while ensuring a minimum flight time of 60 minutes. With a cruise speed of 15 m/s, the AerGo has a range of 40 km. The pilot’s longitudinal position, optimized at 1.6 m, ensures stability. The upper wing has a positive stagger of 0.45 m forward, creating a seesaw effect that smooths weight-shift control. Roll is controlled by wing warping, and yaw by rudders placed at the wing tips. A 15° wing sweep enhances rudder effectiveness, allowing safe operation on a single engine.

The aircraft’s lightweight structure consists of a skin-on-frame design, with a nylon-covered carbon fiber wing weighing 11.3 kg and a dacron-covered carbon fiber hull at 4 kg. Noise reduction is achieved with six-blade propellers, keeping levels below 40 dB at 100 m distance. Approximately 74% of the aircraft is recyclable, with a carbon footprint of 800 kg CO2 per unit.

At an estimated price of €20,000 per unit and annual sales of 20, the break-even point is 9.5 years, with a projected return on investment of €700,000 after 12 years. Further analysis is required on cost budgeting, structural impact resistance, and user assembly instructions to ensure feasibility.