Unsinkable Aluminum Tubes Developed With Spider-Inspired Surface

Researchers have introduced a new approach to maritime engineering by developing aluminum tubes that maintain buoyancy even after damage, using surface patterns inspired by aquatic spiders. This advancement offers potential for more resilient floating structures and devices in challenging environments.

The team at the University of Rochester designed these tubes with superhydrophobic surfaces created through femtosecond laser etching, which forms intricate micro- and nanoscale structures on the metal. These patterns enable the tubes to trap air and repel water, allowing them to float even when punctured or exposed to corrosive conditions.

Unlike previous floating-disk prototypes, the tubular design retains trapped air in various orientations, including vertical and tilted positions, which enhances stability in rough water. Laboratory tests showed that the tubes remained buoyant after being damaged with multiple holes and when submerged in both freshwater and saltwater for extended periods.

The underlying mechanism relies on superhydrophobicity and the plastron effect, where air layers on textured surfaces prevent water from entering the metal. The surface treatment does not depend on additional coatings, making it more durable and resistant to wear compared to conventional waterproofing methods.

What the numbers show

• The research was published on January 27, 2026
• Tubes tested for six months in Lake Ontario and in saltwater
• Current tube prototypes measure nearly half a meter in length

Guo’s research group demonstrated that rafts built from these tubes could generate electricity by harvesting wave energy. The technology is also being considered for use in modular rafts, emergency flotation devices, buoys, and floating platforms for renewable energy applications.

The laser-etched surface is intrinsic to the aluminum, permanently changing its water-repellent properties. Researchers indicated there are no technical barriers to producing larger tubes using more powerful lasers, which could expand the range of practical applications.

Potential uses for this technology include floating solar panel installations, aquaculture systems, and infrastructure to support coastal communities affected by rising sea levels. The design aims to reduce the risk of maritime disasters by preventing vessels or platforms from sinking, which can help avoid oil spills and cargo loss.

Earlier work by the same research group in 2019 focused on floating disks, but those shapes were less effective at retaining air during turbulent conditions. The current tubular approach addresses this limitation, providing improved performance in dynamic marine environments.

* This article is based on publicly available information at the time of writing.