This article summarizes reporting by the Chicago Tribune and official announcements from AkzoNobel. This article summarizes publicly available elements and public remarks.

AkzoNobel Invests $58 Million to Modernize Waukegan Aerospace Hub

AkzoNobel has announced a significant capital injection of €50 million (approximately $58 million) into its Waukegan, Illinois, facility, solidifying the site’s status as the company’s largest aerospace coatings production plant in the world. According to reporting by the Chicago Tribune and official company statements released in early January 2026, the project aims to modernize manufacturing capabilities and expand capacity to meet surging global travel demand.

The investment involves a strategic reorganization of AkzoNobel’s North American footprint. While the Waukegan site will focus on intensified manufacturing, warehousing operations are set to relocate to a new facility in Pleasant Prairie, Wisconsin. This shift allows the company to repurpose existing storage space in Illinois for production lines, directly addressing the need for higher output.

Scope of the Expansion

The upgrade focuses on what AkzoNobel describes as “Industrial Excellence,” a program designed to streamline operations through advanced automation and improved workflow. The Waukegan facility, located at 1 East Water Street, currently spans 11 acres and employs approximately 200 people.

According to details shared in the company’s announcement, the modernization will be executed in two phases. The primary goal is to enhance supply chain resilience in North America, offering shorter lead times for airline and MRO (Maintenance, Repair, and Operations) customers.

Technological Upgrades

The investment will fund the installation of state-of-the-art machinery intended to increase throughput and consistency. Key technical enhancements include:

• Liquid Pre-Batch Area: A dedicated zone designed to improve the efficiency of mixing and preparing coating formulations.
• High-Speed Dissolvers: New technology aimed at accelerating the dissolving process for various coating components.
• Rapid Service Unit: A specialized operational unit focused on the MRO market, ensuring faster turnaround times for urgent aircraft repair needs.

Strategic Context and Market Demand

The decision to expand comes as the aerospace industry prepares for a projected rise in global air travel. Airlines and manufacturers are increasingly requiring specialized coatings for both new aircraft deliveries and the maintenance of existing fleets. By moving finished goods storage to the new Wisconsin facility, AkzoNobel expects to significantly increase its production capacity for primers, basecoats, clearcoats, and custom colors.

Patrick Bourguignon, Director of AkzoNobel’s Automotive and Specialty Coatings business, emphasized the strategic necessity of the move in a press statement:

“This investment will increase our comprehensive North American supply capability and solidify our position as a frontrunner in the aerospace coatings industry. Demand for air travel is expected to grow significantly over the next few years and we want to make sure our customers are able to meet that demand with aircraft of the highest quality.”

Operational Flexibility

Beyond raw capacity, the upgrades are designed to offer greater flexibility in production batch sizes. Martijn Arkesteijn, Global Operations Director for AkzoNobel Aerospace Coatings, noted that the improvements would directly benefit customer timelines.

“We’ll be able to provide current and future customers with even more flexibility through the delivery of large batch sizes, better responsiveness to market needs and shorter lead time for color development.”

Sustainability Targets

While the primary focus of the investment is operational efficiency, AkzoNobel has stated that the project aligns with its broader environmental goals. The company aims to reduce carbon emissions by 50% by 2030 (using a 2018 baseline) and transition toward 100% renewable electricity. The new equipment installed at the Waukegan plant is expected to reduce energy intensity per unit of production, supporting these corporate sustainability targets.

AirPro News Analysis

The separation of manufacturing and warehousing is a growing trend among industrial suppliers facing land constraints in established industrial zones. By decoupling storage from production, AkzoNobel effectively unlocks new square footage for value-added manufacturing without the need to acquire adjacent land, which can be difficult in developed areas like Waukegan. This move suggests a prioritization of speed and volume, critical factors as the aerospace supply chain continues to recover and expand post-pandemic.

Sources

Sources: Chicago Tribune, AkzoNobel Official Announcements

This article is based on an official press release from Daher.

Daher Wins 2026 JEC Innovation Award for Thermoplastic Wing Rib

On January 12, 2026, the French industrial conglomerate Daher was announced as the winner of the prestigious 2026 JEC Composites Innovation Award in the “Aerospace – Parts” category. The award recognizes the company’s development of a “Highly Loaded Thermoplastic Wing Rib,” a critical structural component designed to meet the rigorous demands of future single-aisle Commercial-Aircraft programs.

According to the company’s announcement, this innovation represents a significant leap forward in the application of thermoplastic composites. While previous applications were often limited to thinner, secondary parts, this project demonstrates the viability of thermoplastics for thick, primary aerostructures that must withstand heavy mechanical loads.

Breaking Boundaries in Composite Manufacturing

The award-winning component is a structural breakthrough for the aerospace industry. Traditionally, primary structures like wing ribs, which maintain the aerodynamic shape of the wing and transfer loads between the skin and spars, have been manufactured using aluminum or thermoset composites that require lengthy autoclave curing cycles.

Daher’s new rib is a thick laminate structure consisting of up to 64 plies, reaching a thickness of approximately 12mm. By successfully manufacturing a part of this density and complexity using thermoplastics, Daher has proven that the material can replace metal in the most demanding areas of an airframe.

Collaborative Development

The project was executed through a strategic consortium involving several key European partners, each contributing specialized expertise to the Manufacturing chain:

• Victrex (UK): Supplied the specific material, a Carbon Fiber Reinforced Thermoplastic (CFRTP) using LMPAEK (Low Melt Polyaryletherketone) unidirectional tape.
• LIST (Luxembourg): Developed a novel Infrared (IR) welding process to assemble the rib.
• CETIM (France): Designed the mechanical test bench to validate the component under flight-certification loads.
• AniForm (Netherlands): Provided advanced simulation Software to predict distortion and ensure “first-time-right” manufacturing.

Technical Innovations and Process Efficiency

The success of the “Highly Loaded Thermoplastic Wing Rib” relies on the integration of two patented processes that streamline production and eliminate traditional manufacturing bottlenecks.

First, the rib utilizes Direct Stamping®, a Daher-patented process. According to the press release, this technique eliminates the intermediate “consolidation” step typically required between layering fibers (layup) and the stamping phase. By removing this step, the production cycle is significantly shortened, and energy consumption is reduced.

Second, the assembly utilizes Infrared (IR) Welding, a patent held by the Luxembourg Institute of Science and Technology (LIST). Instead of using heavy metal rivets or bolts to assemble the rib’s T-shaped profile, the partners used IR welding to create a continuous, integrated composite structure. This approach eliminates the weight of fasteners and improves the overall integrity of the part.

“This JEC Award rewards our commitment to advancing composite technologies for aeronautics. We believe in it: by combining innovative materials and advanced processes, we demonstrate that it is possible to combine performance, competitiveness, and reduction of the carbon footprint.”

, Dominique Bailly, R&D Director at Daher

Performance Metrics and Environmental Impact

The shift to thermoplastics and the elimination of fasteners has yielded quantifiable performance improvements. Data provided by Daher highlights the following metrics for the new wing rib compared to traditional aluminum or bolted metal assemblies:

• Weight Reduction: The component is 22% lighter than its aluminum equivalent.
• Cost Efficiency: Assembly costs are reduced by 15% compared to bolted metal solutions.
• Production Speed: The overall production cycle time is reduced by 25%.
• Sustainability: The technology saves an estimated 12.5 tons of CO₂ per rib over the lifecycle of a single-aisle aircraft.

AirPro News Analysis

The significance of this award extends beyond a single component; it addresses the “holy grail” of next-generation aircraft manufacturing: rate. As Airbus and Boeing look toward successors for the A320 and 737 families, they face the requirement of producing wings at unprecedented rates, potentially 75 to 100 aircraft per month.

Traditional thermoset composites, while light, are chemically slow to cure, creating a bottleneck in the factory. Thermoplastics, which can be stamped, melted, and welded in minutes, are widely viewed as the necessary enabler for these high-rate programs. By demonstrating that thermoplastics can handle the structural loads of a primary wing rib, Daher is positioning itself as a critical supplier for the “Wing of Tomorrow.” Furthermore, the use of induction welding (seen in their 2025 Torsion Box project) and now IR welding suggests Daher is building a diverse toolkit of joining technologies to eliminate rivets entirely from future airframes.

Frequently Asked Questions

What is LMPAEK?

LMPAEK stands for Low Melt Polyaryletherketone. It is a high-performance thermoplastic polymer that offers high heat resistance and mechanical strength but can be processed at lower temperatures than traditional PEEK, making it faster and more energy-efficient to manufacture.

Why is Infrared (IR) welding important?

IR welding allows for the assembly of composite parts without mechanical fasteners like rivets or bolts. This reduces the overall weight of the aircraft and eliminates the labor-intensive process of drilling thousands of holes, which speeds up production.

What is the primary advantage of thermoplastics over thermosets?

Unlike thermosets, which undergo a permanent chemical change during curing and cannot be reshaped, thermoplastics can be melted and reshaped multiple times. This makes them recyclable and allows for much faster manufacturing cycles (minutes vs. hours).

Sources: Daher

This article is based on an official press release from ASG Helicopter Services.

ASG Helicopters Services Introduces First Leonardo AW189 to Caspian Region

ASG Helicopter Services (ASG), a prominent aviation operator based in Azerbaijan, has officially integrated its first Leonardo AW189 helicopter into its fleet. The delivery, celebrated during a presentation on December 17, 2025, marks a significant operational milestone as the first aircraft of its type to enter service in the Caspian Sea region, covering Central Asia and the Caucasus.

According to the company’s announcement, this delivery is the first of two units ordered to support offshore oil and gas operations. The second unit is scheduled for delivery in early 2026. The acquisition was executed through a partnership involving ASG, the manufacturer Leonardo Helicopters, and Exclases Group, the exclusive distributor for Leonardo in the region.

Operational Capabilities and Configuration

The newly delivered AW189 has been supplied in a specialized offshore configuration designed to meet the rigorous demands of the energy sector. ASG Helicopter Services states that the aircraft is tailored for long-range transport and overwater safety, bridging the operational gap between the company’s medium-class AW139s and heavy-class Sikorsky S-92As.

The “super-medium” class helicopter features a maximum take-off weight (MTOW) of approximately 8.3 to 8.6 tonnes and is configured to carry 16 passengers plus two pilots. Key safety specifications highlighted in the release include a main gearbox capable of a 50-minute “run-dry” operation, exceeding standard certification requirements, and a Full Ice Protection System (FIPS) to manage the challenging winter conditions of the Caspian region.

Strategic Fleet Modernization

ASG Helicopter Services indicated that the introduction of the AW189 is part of a broader strategy to modernize its fleet and enhance service offerings for major clients such as SOCAR, BP, and TOTAL. By adopting the super-medium platform, the operator aims to provide a more cost-efficient solution for missions that require significant range and payload but do not necessitate the full capacity of a heavy helicopter.

Azer Sultanov, Head of ASG Helicopter Services, emphasized the importance of this acquisition for the company’s future operations:

“Next-generation helicopters represent a significant new era for ASG Helicopter Services. The integration of the AW189 helicopter into our offshore operations strengthens our capability to meet the evolving needs of customers in the oil, gas, and energy sectors, while ensuring the highest standards of safety, reliability, and operational efficiency.”

The company confirmed that the aircraft has already received all necessary registration and airworthiness certificates from the Civil Aviation Authority of Azerbaijan.

AirPro News analysis

The arrival of the AW189 in the Caspian region reflects a wider global trend in the offshore energy sector: the shift toward “super-medium” rotorcraft. For years, the industry relied heavily on heavy helicopters for deep-water transport. However, volatility in oil prices and advancements in avionics have driven operators toward aircraft that offer near-heavy payload capabilities with the lower operating costs of a medium airframe.

By securing the first AW189 in the region, ASG positions itself as a technological leader in the Central Asian market. This move likely anticipates stricter safety standards from International Oil and Gas Producers (IOGP), which increasingly favor modern airframes equipped with advanced terrain awareness and run-dry capabilities. We expect this acquisition to place pressure on regional competitors to upgrade their legacy fleets to maintain contracts with international oil majors.

Technical Specifications and Safety

The AW189 is powered by two General Electric CT7-2E1 engines, providing the necessary power for long-range missions to remote rigs. According to manufacturer data referenced in the report, the aircraft includes a suite of advanced avionics designed to reduce pilot workload and enhance situational awareness.

• Range: Approximately 440-600 nautical miles, depending on payload.
• Emergency Systems: Equipped with life rafts, emergency floats certified up to Sea State 6, and Helicopter Emergency Exit Lighting Systems (HEELS).
• Avionics: Glass cockpit with 4-axis autopilot, Helicopter Terrain Awareness and Warning System (HTAWS), and Traffic Collision Avoidance System (TCAS II).

ASG Helicopter Services, which already operates as an Authorized Service Center for Leonardo’s AW139 and AW109 models, will extend its maintenance capabilities to support the new AW189 fleet.

Frequently Asked Questions

What is the primary role of the new AW189?
The helicopter is configured for offshore transport, ferrying personnel and supplies to oil and gas platforms in the Caspian Sea.

How many passengers can it carry?
In its current offshore configuration, the aircraft seats 16 passengers and 2 pilots.

When will the second unit arrive?
ASG expects to take delivery of the second AW189 in early 2026.

Sources

• ASG Helicopter Services Press Release