Sustainability
Aerodynamic
seals.
Bringing aero smoothness
Aerodynamic seals are aeronautics components used to improve the aircraft aerodynamic smoothness, reducing the physic vector know as drag and, consequently, making the aircraft more efficient with a reduced fuel consumption. In addition, the aerodynamic seals contributes to:
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Reduce external noise;
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Reduce emissions;
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Reach more speed;
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Increase the aircraft residual value;
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A superior climb and cruise characteristics;
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Improved stall characteristics.
In the diagram below is shown an airplane wing cross section in two distinct conditions:
with and without aerodynamic sealing.
Conception & CFD Analysis
Feasible Design
During the development, gaps and steps are inevitable.
Seal Implementation
Aerodynamic seals bring the real surface closer to the ideal shape.
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Ideal shape;
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Mathematical smooth surface;
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No gaps, no steps.
When you choose an Enflexus seals solution, you choose sustainability and economics benefits. This is one of the reasons of our success: our customers are able to confirm or measure benefits in a very expressive way. The world aviation community has recognized that the sealing solutions contributes considerably not only to the aircraft fuel burn reduction, but reduce the aircraft external noise and emissions as well. This is definitely that’s matter: engineering solutions that can protect the environment and guarantee a sustainable path to the future.
Fuel burn and
emission reduction.
Direct emissions from aviation account for around 2.5% of total global CO2 emissions — and the global aviation industry produced 882 million tonnes of CO2 in 2023, out of roughly 43 billion tonnes produced by humanity as a whole. The industry has set a goal of net-zero carbon emissions by 2050, supported by efficiency measures, energy transition initiatives, and continued technological innovation across the sector.
Source: Air Transport Action Group (ATAG), Facts & Figures, and Our World in Data.
One of the most important drive to adopt the aerodynamic seals solutions is related to the aircraft drag coefficient reduction and consequently the fuel burn reduction. In the world aviation community there are too many case studies that show the benefits around to 5% of fuel consumption reduction, when we compare a aircraft with and without aerodynamic seals installed.
A Monte Carlo simulation brings us a good example of a simplified market value analysis, considering just 1% of fuel consumption reduction(1): almost 90% of analyzed scenarios, this 1% could worths more than USD 160,000 (2) over the aircraft price. The rationale is that after 24 months(3) the airline can recovery its investment.
It is important to highlight that this simulation considers only 1% of fuel consumption reduction. For an aerodynamic gain equals 3%, the market value could reach USD 480,000.
1. Fuel consumption reduction for a typical regional airplane: two turbofan engines, around 200 pax capacity. Considering 1.1. The block fuel measurement (between engines start to shutdown, including airplane taxi and ICAO fuel reserve rules); 1.2. Typical mission length of 600nmi.
2. Oil price considered: USD 75/barrel.
3. Airline payback accepted terms.
The amount of CO2 emitted from kerosene-burning aircraft engines depends solely on the amount of fuel consumed. If alternative fuels are considered, the specific CO2 emission per kg fuel changes, but fundamental rules of aircraft fuel consumption still apply.
The figure beside is the IATA Emissions reduce roadmap that shows the commitments assumed for all important players involved in the aeronautical business. The goal is reduce CO2 emissions by 50% until 2050.
Noise
reduction.
Aircraft noise is the most significant cause of adverse community reaction related to the operation and expansion of airports. This is expected to remain the case in most regions of the world for the foreseeable future.
There's no getting away from the fact that aviation can be noisy. When aircraft land and take off - and, depending on the aircraft and its altitude, as they fly overhead - they produce a considerable amount of noise.
When the airport neighborhood community is evaluated, noise always is one of the most important adverse aspects of the community environment.
The aeronautical seals brings better results in external noise when installed in strategic location on the airplane.
External noise measurement
Green
fleet.
The actions for the search of aircraft with lower burn emissions and noise have expanded worldwide, being the base of world politics of many companies.
One of the best-known eco friendly policies in the aviation industry is the policy of the airline Flybe. The company has created an ecolabel with noise and emissions ratings.
EU Flight Emissions Label
Since 2025, the European Union has taken a significant step toward transparency in aviation sustainability with the Flight Emissions Label (FEL), a regulation adopted by the European Commission in December 2024 and led by the European Union Aviation Safety Agency (EASA). When booking flights within the EU, passengers can now see standardized information on a flight's carbon footprint and carbon efficiency.
In November 2025, EASA and IATA (International Air Transport Association) signed a Memorandum of Understanding to align the EU Flight Emissions Label with IATA's own sustainability data systems, aiming to make emissions data consistent and accessible across the industry.
This kind of industry-wide push toward transparency reflects exactly why aerodynamic sealing solutions matter: every improvement in drag reduction and fuel efficiency contributes directly to the metrics now being measured, reported, and increasingly expected by regulators, airlines, and passengers alike.