The AIL‑SMA project, carried out by Deharde GmbH in partnership with ETW and Boeing, focused on the maturation and integration of shape‑memory‑alloy (SMA) actuated components for civil aircraft. The overarching goal was to demonstrate that SMA‑driven vortex generators (VGs) could be actively deployed during critical flight phases such as take‑off and landing, while being retracted during cruise to minimise drag. This capability would provide a new level of aerodynamic flexibility without adding significant weight or complexity.

In the first work package the team defined the technical requirements and design constraints for an SMA‑based VG system. The design had to accommodate the high temperature gradients and pressure loads experienced on a side‑lift‑wing (SLW) while ensuring rapid actuation and reliable operation over the aircraft’s service life. The SMA material chosen was a nickel‑titanium alloy with a transformation temperature tuned to the expected operating envelope. The actuator was integrated into a compact, foldable VG that could be stowed flush with the wing surface when not in use.

The second work package produced a full‑scale prototype that was mounted on a test rig. Finite‑element analysis (FEA) was performed to verify structural integrity under the worst‑case load case, and the results confirmed that the VG could withstand the expected aerodynamic forces without exceeding the material’s elastic limit. The prototype was then installed on a test aircraft and flown in a series of controlled flight tests. During take‑off and approach the VG was deployed, generating a controlled vortex that increased lift and reduced stall speed. In cruise the VG was retracted, and the aircraft’s drag coefficient was measured in a wind‑tunnel test at the PETW facility. The data showed a measurable reduction in drag when the VG was stowed, confirming the anticipated benefit of the active system. Although the report does not publish the exact percentage, the reduction was significant enough to justify further development.

The third work package involved the integration of the SMA‑VG into a production‑grade aircraft. The system was instrumented with temperature sensors and a control interface that allowed the pilot to command deployment based on flight conditions. The final flight test demonstrated that the VG could be reliably actuated multiple times during a single flight without failure, and that the aerodynamic benefits were consistent with the earlier test results. The project also produced a detailed design package that can be transferred to Boeing’s production line, positioning Deharde as a Tier‑1 supplier for SMA actuators in the aerospace sector.

Collaboration was central to the project’s success. Deharde led the design, manufacturing, and testing of the SMA components, while ETW provided the high‑temperature testing environment and expertise in material science. Boeing supplied the aircraft platform, flight test facilities, and aerodynamic analysis tools, and also acted as the primary customer for the final product. The project was funded through a joint European research grant, with contributions from the German Ministry of Education and Research and the European Union’s Horizon programme. The timeline spanned three work packages over a two‑year period, with milestones set for requirement definition, prototype development, and full integration. The outcomes of AIL‑SMA build on the earlier ISL‑SMA project, extending the technology from a laboratory prototype to a flight‑qualified system and opening new opportunities for SMA applications across multiple industries.