Unsinkable aluminum tubes could transform ocean energy technology: Study

Researchers have engineered a novel aluminum structure capable of remaining afloat even when punctured, potentially revolutionizing ocean-energy technologies and floating platform design. The development, led by Chunlei Guo, a professor of optics and physics at the University of Rochester, was published last month in the journal Advanced Functional Materials and reported by The New York Times on Sunday.

Microscopic Engineering for Buoyancy

The narrow aluminum tubes, approximately one-fifth of an inch in diameter, rely on microscopic surface patterns that repel water—a property known as superhydrophobicity. By chemically etching tiny pits into the aluminum, researchers prevented water from entering, enabling trapped air to remain intact even when structures are damaged. "It will still stay floating," Guo said. "We have done quite extensive, really harsh environmental testing." Laboratory trials confirmed the tubes resisted corrosion and algae buildup while maintaining buoyancy in both saltwater and biologically active environments.

Applications and Inspiration

"I think the ocean is still a vast untapped resource," Guo noted, suggesting the technology could help harvest power from ocean waves or support long-lasting marine infrastructure. Numerical modelling indicates layered assemblies could withstand severe ocean conditions. Andreas Ostendorf, a professor of applied laser technology at Ruhr-University Bochum, described the approach as promising. "As researchers, especially in engineering, we are always looking for disruptive ideas. This can be a roadmap toward really penetrating this technology in many applications."

Nature-Inspired Design

The work builds on years of research into engineered surfaces inspired by natural systems such as diving bell spiders and fire ants, which use water-repellent structures to trap air and survive underwater or during floods. Scientists noted further real-world testing will be needed, but the design could open new paths for durable floating devices and renewable energy systems powered by ocean motion.