Scientists at the university used advanced X-ray imaging techniques to examine fossilised bones of the prehistoric flying reptile to reveal details of its structure that have not been seen before.
Early pterosaurs typically had wingspans of about 2m, but later pterosaurs evolved with wingspans reaching upwards of 10m. The size means they had to solve multiple engineering challenges to get their wingspan airborne, such as supporting their long wing membrane predominantly from a single finger.
The team found that pterosaur bones contain a complex network of tiny canals, making them lightweight and very strong.
The researchers said these ancient adaptations could start a palaeo-biomimetics ‘revolution’, using the biological designs of prehistoric creatures to develop new materials. The findings are published today (February 11, 2025) in Scientific Reports.
In a statement, lead author Nathan Pili, a PhD student at Manchester University, said: “We are so excited to find and map these microscopic interlocking structures in pterosaur bones, we hope one day we can use them to reduce the weight of aircraft materials, thereby reducing fuel consumption and potentially making planes safer.”
The team used X-ray Computed Tomography (XCT) to scan the fossil bones at near sub-micrometre resolution. They found that the network of tiny canals and pores within pterosaur bones - once used for nutrient transfer, growth, and maintenance - also help protect against microfractures by deflecting cracks.
By replicating these natural designs, engineers could create lightweight, strong components that also incorporate sensors and self-healing materials, which could lead to more complex and efficient aircraft designs. The team suggests that advances in metal 3D printing could turn these ideas into reality.
Professor Phil Manning, a senior author of the study from Manchester University, said: “There is over four billion years of experimental design that were a function of Darwinian natural selection. These natural solutions are beautifully reflected by the same iterative processes used by engineers to refine materials.
“It is highly likely that among the billions of permutations of life on Earth, unique engineering solutions have evolved but were lost to the sands of time. We hope to unlock the potential of ancient natural solutions to create new materials but also help build a more sustainable future. It is wonderful that life in the Jurassic might make flying in the 21st Century more efficient and safer.”
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