MRO & Manufacturing
Sikorsky and Partners Open S-92 Helicopter Center of Excellence in Brazil
Sikorsky, Heli-One, and Milestone launch an S-92 Helicopter Center of Excellence in Brazil to enhance maintenance and reduce downtime.
Strategic Cooperation: Sikorsky, Heli-One, and Milestone Establish S-92® Helicopter Center of Excellence in Brazil
In a strategic move reflecting the evolving needs of the global Helicopters services industry, Sikorsky (a Lockheed Martin company), Heli-One (a division of CHC Helicopter Group), and Milestone Aviation announced on July 24, 2025, the creation of a Center of Excellence (CoE) for S-92® helicopters in Rio de Janeiro, Brazil. The initiative is designed to strengthen operational support across South America, enhancing maintenance capabilities and reducing fleet downtime for one of the most widely used helicopters in offshore oil and gas missions.
This collaboration addresses a growing demand in Brazil’s offshore energy sector, where the S-92 has become a critical asset for crew transport and search-and-rescue (SAR) operations. With over 30 S-92 helicopters currently operating in the region, the establishment of a dedicated CoE marks a significant step toward localized, efficient, and scalable maintenance and logistics support.
The announcement also aligns with broader industry trends emphasizing the importance of regional maintenance hubs to mitigate supply chain challenges and improve aircraft availability. As operators face increasing logistical complexities, this initiative aims to provide timely access to parts, technical expertise, and scheduled maintenance services, all within Brazil’s borders.
Background: The S-92 and Its Role in Brazil
Developed by Sikorsky and introduced in 2004, the S-92 helicopter is a twin-engine, medium-lift aircraft known for its robust safety credentials and versatility. With more than 2.2 million fleet flight hours logged globally, the S-92 supports a range of missions, including offshore oil transport, executive transport, and SAR operations. Its performance in high-demand environments has made it a preferred choice for operators in regions with expansive offshore energy infrastructure.
In Brazil, the S-92 plays a vital role in supporting the operations of Petrobras, the state-owned oil company, and other operators such as CHC Brazil, Lider Aviation, and Omni Helicopters. These helicopters are primarily used to ferry personnel between the mainland and offshore oil platforms located in deepwater fields, including the pre-salt reserves off the southeast coast.
Before the CoE initiative, support for the S-92 fleet in Brazil was limited to a Forward Stocking Location (FSL) in Rio de Janeiro. While helpful, this setup lacked the embedded maintenance and repair capabilities required for rapid response and high availability. Maintenance tasks often required international logistics, contributing to longer downtimes and increased operational costs.
About the Partners
Sikorsky, a Lockheed Martin company, is the original equipment Manufacturers (OEMs) of the S-92. The company has consistently invested in technological upgrades to improve the helicopter’s safety and performance. One such innovation is the Phase IV main gearbox, designed to eliminate “land immediately” requirements during oil-loss emergencies.
Heli-One is the maintenance, repair, and overhaul (MRO) arm of CHC Helicopter Group. With over two decades of experience and support for more than 250 aircraft globally, Heli-One brings extensive technical knowledge and infrastructure to the CoE. It will lead the operations of the new center in Rio de Janeiro.
Milestone Aviation is the world’s leading helicopter leasing company, financing fleets for operators worldwide. In Brazil, Milestone recently leased seven helicopters, including S-92s, to Omni Helicopters International for Petrobras-related missions. This marks Milestone’s first major placement in the Brazilian market.
The Center of Excellence Initiative
The newly announced Center of Excellence will be based in Rio de Janeiro and led by Heli-One. It is designed to provide comprehensive support for the S-92 fleet in Brazil and across South America. The center will offer services such as access to critical spare parts, scheduled maintenance, and optimized supply chain solutions.
The CoE aims to reduce aircraft downtime and improve mission readiness by embedding services closer to operators. Key components like gearboxes, main rotor blades, and dampers will be stocked locally, allowing for quicker turnaround times on maintenance and repairs. This localized approach is expected to alleviate the parts supply bottlenecks that have affected global S-92 operations in recent years.
According to the announcement, the CoE will also integrate Sikorsky’s Phase IV gearbox technology, which is currently undergoing certification. This upgrade enhances the safety profile of the S-92 and reflects a broader commitment to continuous improvement and fleet modernization.
“We are committed to providing rigorous and dependable capabilities that ensure the continued success of the S-92 helicopter,” said Leon Silva, VP of Global Commercial and Military Systems at Sikorsky.
Strategic Importance for Brazil
Brazil’s offshore oil and gas sector is among the most active in the world, with Petrobras leading exploration and production in deepwater and ultra-deepwater fields. The logistical demands of these operations necessitate reliable helicopter transport, especially for platforms located hundreds of kilometers offshore.
CHC Brazil, one of the major operators of the S-92 in the region, recently secured two new contracts with Petrobras for operations in the Roncador field. These Contracts have led to a 33% expansion of CHC’s local fleet, underlining the growing reliance on the S-92 platform.
With over 30 S-92 aircraft operating in Brazil, the CoE is poised to become a critical asset in maintaining fleet availability and operational continuity. By reducing the need for international logistics, the center supports Brazil’s broader goal of developing self-sustaining aerospace capabilities.
Global Industry Context
Globally, the helicopter MRO industry is experiencing transformation, driven by increasing fleet sizes and the need for faster maintenance turnaround. The civil helicopter MRO market is projected to reach $9.2 billion by 2025, with Latin America identified as a high-growth region due to expanding offshore energy activities.
The S-92 has faced challenges in recent years, including parts shortages and long maintenance cycles. In 2024, it was reported that up to 7% of the global S-92 fleet was grounded due to Supply-Chain constraints. These challenges have prompted OEMs and MRO providers to rethink support strategies, leading to the emergence of regional Centers of Excellence.
StandardAero’s MRO facilities in Canada serve as an example of this trend, consolidating services to improve efficiency and reduce downtime. The new CoE in Brazil follows a similar model, tailored to the specific needs of the South American market and its offshore energy sector.
“The time is right for establishing an S-92 Center of Excellence in Brazil as more customers select the aircraft for rescue and recovery,” said Tom Burke, CEO of CHC Helicopter Group.
Future Outlook
The establishment of the CoE represents a long-term investment in the sustainability of Brazil’s helicopter operations. As offshore energy projects expand and become more complex, the demand for reliable aerial transport will only increase. The CoE positions Brazil as a regional hub for S-92 support, potentially attracting additional operators and investment.
Moreover, the Partnerships between Sikorsky, Heli-One, and Milestone demonstrates a collaborative approach to addressing industry-wide challenges. By pooling resources and expertise, the companies aim to set a benchmark for future MRO collaborations in the region and beyond.
While the initiative is still subject to internal approvals, its successful implementation could serve as a model for other regions facing similar logistical and operational constraints.
Conclusion
The strategic cooperation between Sikorsky, Heli-One, and Milestone to establish a Center of Excellence for S-92 helicopters in Brazil marks a significant milestone for the region’s aviation and energy sectors. By localizing critical maintenance and supply chain services, the initiative aims to enhance fleet readiness, reduce downtime, and support the growing demands of offshore operations.
As the global helicopter industry continues to evolve, the Brazilian CoE could become a blueprint for how OEMs, MRO providers, and lessors collaborate to deliver integrated, efficient, and reliable support solutions. The move underscores the importance of regional hubs in meeting the operational needs of modern aviation fleets.
FAQ
What is the purpose of the Center of Excellence in Brazil?
The CoE aims to provide localized maintenance, repair, and supply chain services for the S-92 helicopter fleet operating in Brazil and South America.
Who will lead the operations of the CoE?
Heli-One, the MRO division of CHC Helicopter Group, will lead the CoE operations in Rio de Janeiro.
How many S-92 helicopters operate in Brazil?
Over 30 S-92 helicopters are currently in operation in Brazil, primarily supporting offshore oil and gas missions.
Why is the S-92 important for Brazil’s offshore sector?
The S-92 provides reliable transport for personnel and equipment to offshore oil platforms, which are often located far from the mainland.
What challenges does the CoE aim to address?
The CoE addresses parts shortages, long maintenance cycles, and the need for faster, localized support to reduce fleet downtime.
Sources
Photo Credit: Lockheed Martin
MRO & Manufacturing
Baxter Aerospace Invests $19.55M in Utah Manufacturing Facility
Baxter Aerospace expands into Washington County, Utah with a $19.55M facility to scale UAS and satellite comms production.
Baxter Aerospace will invest $19.55 million to lease and equip a new manufacturing facility in Washington County, Utah, transitioning its unmanned aircraft and communications systems from prototype development into full-scale production.
The expansion, announced in an October 8, 2026, press release by the Utah Governor’s Office of Economic Development (GOED), is projected to create 90 high-paying jobs over the next five years while strengthening the state’s aerospace and defense industrial base.
Transitioning to full-scale production
The new facility in Washington City will feature high-capacity infrastructure, specialized testing spaces, and security systems. This site is designed to support mission-critical work across aerospace, defense, satellite communications, autonomous aircraft, and public safety.
Baxter Aerospace CEO Jeff Baxter stated that expanding in southern Utah allows the company to increase manufacturing capacity and support growing customer needs. He noted the company is prepared to help shape the region’s aerospace future.
The project is backed by a Rural Economic Development Tax Increment Financing (REDTIF) post-performance tax credit approved by the GOED. Under the agreement, Baxter Aerospace can earn a rebate of up to 30% on new state revenues generated over the five-year term, capped at $456,939.
State officials project the expansion will generate $20,758,160 in new state wages and $1,523,131 in new state tax revenue during that period. GOED Commissioner Jefferson Moss noted that the investment signals Utah’s economic future is fueled by frontier innovation. Washington County Commissioner Adam Snow added that the expansion connects local talent with emerging aerospace opportunities.
Scaling the BA-1 Dragonfly and defense portfolio
The manufacturing expansion follows a period of steady growth for the St. George-based defense and aerospace innovator. Brothers Jeff and Michael Baxter founded the company in 2015 following a severe Oregon wildfire, focusing their initial efforts on real-time sensing, resilient communications, and autonomous systems for emergency response and defense applications.
The company’s flagship aerospace product is the BA-1 Dragonfly. The Dragonfly is a Group 3 vertical takeoff and landing (eVTOL) unmanned aircraft system designed for intelligence, surveillance, and reconnaissance (ISR) missions, featuring over 12 hours of endurance.
Alongside the BA-1 Dragonfly, Baxter Aerospace produces deployable broadband satellite communications kits that utilize low Earth orbit (LEO) networks. The company also manufactures precision components for the fusion and nuclear energy sectors.
To support the scaling of these product lines, Baxter Aerospace secured a $6 million Series A funding round in July 2025. The capital was raised from the Department of Defense (DoD) Accelerator fund, managed by Accuidity Capital Management, specifically to accelerate production of the Dragonfly system and the deployable communications kits. The new Washington County facility represents the physical infrastructure required to execute that production scale-up between late 2026 and 2031.
Photo Credit: Utah Governor’s Office of Economic Development
MRO & Manufacturing
IAI 777-300ERSF P2F Conversions Launch in North America
The first Boeing 777-300ER for P2F conversion in North America arrives at Ascent Aviation Services in Marana, Arizona.
The first Boeing 777-300ER slated for passenger-to-freighter (P2F) conversion in North America arrived at Ascent Aviation Services in Marana, Arizona, on October 22, 2026. The induction marks the regional launch of the Israel Aerospace Industries (IAI) modification program for the widebody twinjet.
The arrival of the World Star Aviation aircraft initiates operations at a newly expanded site designed to increase global capacity for the Boeing 777-300ERSF program, according to a joint press release issued by the companies.
Expanding global conversion capacity
Ascent Aviation Services, an independent aircraft aftermarket service provider and Federal Aviation Administration (FAA) Class IV Part 145 certified repair station, will operate two parallel conversion lines at its Pinal Air Park campus. To accommodate the Boeing 777-300ERSF program, the company invested $70 million to construct two 90,000-square-foot widebody hangars. Ascent broke ground on the facilities on March 29, 2024, effectively tripling the site’s hangar capacity.
“The launch of Boeing 777-300ERSF conversions in North America marks an important milestone for IAI’s global conversion program,” Yaacov Berkovitz, executive vice president and general manager of IAI Aviation Group, stated in the release. “Together with Ascent Aviation Services, we are expanding production capacity and bringing our conversion capabilities closer to customers in the region.”
Ascent Aviation Services chief executive officer David Querio noted that the induction represents the beginning of a long-term partnership with IAI, with multiple Boeing 777-300ERSF conversions planned for the Marana site.
“Our vision is to shape the future of aviation by turning engineering innovation into lasting value for our customers,” IAI president and chief executive officer Guy Bar Lev added. “Passenger-to-freighter conversions are a key part of that vision, extending the productive life of aircraft and helping airlines adapt to changing market needs.”
World Star Aviation’s fleet strategy
The inaugural aircraft belongs to World Star Aviation, a full-service aircraft and engine lessor headquartered in London. The company specializes in mid-to-late life assets and manages a portfolio of approximately 150 aircraft and engines. This includes 60 narrowbody and widebody freighters currently on lease to cargo operators globally.
World Star Aviation partner Yoyo Allalouf cited the strength of the IAI program during a critical period for widebody passenger-to-freighter production as the primary driver for their selection.
“IAI’s dominance in the widebody P2F space, demonstrated by its Boeing 747 and 767 programs, together with our long-standing relationship, underpinned our decision to choose IAI for the 777-300ERSF,” added Garreth Slevin, partner at World Star Aviation.
The rise of the “Big Twin” freighter
The Boeing 777-300ERSF program, marketed as “The Big Twin,” launched on October 22, 2019, as a joint venture between IAI and GECAS, which was subsequently acquired by AerCap. It remains the only certified P2F conversion program for the Boeing 777-300ER.
The converted freighter offers 25 percent more cargo volume than a production Boeing 777-200LRF and 15 percent more volume than a Boeing 747-400BCF. This capacity positions the aircraft as a direct replacement for aging Boeing 747-400 and McDonnell Douglas MD-11 freighter fleets.
IAI brings over 50 years of experience to the program, having delivered more than 350 converted cargo aircraft across Boeing 747, 767, 737, and Airbus A330 platforms. The company currently holds a dominant market share in medium-size freighter conversions, particularly with the Boeing 767.
The 777-300ERSF recently transitioned from certification into commercial service. In August 2026, Challenge Group took delivery of its second 777-300ERSF, which marked the fifth redelivery of the type across the industry for the year.
AirPro News analysis
We view the activation of the Marana conversion lines as a critical step in maturing the Boeing 777-300ERSF program. By establishing a North American footprint, IAI mitigates geographic bottlenecks and provides operators with a domestic option for heavy modifications. The $70 million infrastructure investment by Ascent Aviation Services indicates strong long-term confidence in the widebody conversion market, even as the air cargo sector normalizes following pandemic-era peaks. As legacy quad-engine and tri-engine freighters approach mandatory retirement or become economically unviable, the availability of parallel conversion lines in the United States ensures IAI can capture a significant share of the impending widebody replacement cycle.
Photo Credit: IAI
MRO & Manufacturing
Cirrus Aircraft Breaks Ground on $8M Engine Run-Up Center
Cirrus Aircraft begins construction on a 15,000-sq-ft Engine Run-Up Center in Duluth, MN, set to open summer 2027.
Cirrus Aircraft has commenced construction on an $8 million, 15,000-square-foot Engine Run-Up Center in Duluth, Minnesota, moving critical engine testing and fuel calibration processes into a year-round, climate-controlled environment.
The new facility, detailed in a company press release on October 23, 2026, is designed to support the certification process for the SR Series, Vision Jet, and TRAC10 aircraft while reducing noise at the surrounding airport.
Centralizing certification operations
The Engine Run-Up Center will consolidate several final-phase manufacturing steps into a single enclosed building. The facility will house two calibration stalls dedicated to engine setup and testing, utilizing an 8-foot exhaust collector to ventilate the spaces. A separate climate-controlled control room will allow technicians to conduct data analysis during the testing phase.
In addition to the testing stalls, the building will include two stalls specifically engineered for fueling and defueling aircraft. These areas incorporate specialized fire protection systems and are designed to meet requirements for handling flammable fluids.
Cirrus Chief Executive Officer Zean Nielsen stated that engine run-ups and fuel system calibration are essential processes across aircraft manufacturing. He noted that the modern facility will allow the company to streamline these critical operations, improve efficiency, and provide team members with a dedicated environment to perform the work.
Expanding the Duluth manufacturing footprint
The new testing center adds to an existing corporate footprint that exceeds 1.3 million square feet. The majority of this infrastructure is located in Duluth, which serves as the primary production hub for the manufacturer.
Founded in 1984 and now publicly traded on the Hong Kong Stock Exchange, Cirrus has manufactured more than 12,000 SR Series piston aircraft and Vision Jets to date. The groundbreaking follows closely on a major program milestone for the company. On October 21, 2026, Cirrus celebrated the 10-year anniversary of Federal Aviation Administration (FAA) type certification for the Vision Jet, the first single-engine personal jet to reach the market.
Patrick Waddick, President of Innovation & Operations at Cirrus, highlighted the scale of the company’s historical output in Duluth. He noted that the new facility expands a footprint where the company has produced its entire fleet of over 12,000 aircraft, adding that the manufacturer has spent decades challenging conventions through innovations that transform personal aviation.
Project timeline and operational impact
Construction on the Engine Run-Up Center is underway, with the facility expected to open and become fully operational by the summer of 2027. By moving engine testing indoors, the company anticipates a reduction in noise levels for the surrounding airport environment, a common challenge for manufacturers conducting high-power engine runs on open ramps.
The $8 million investment reflects broader efforts by the airframer to scale production capabilities in response to market requirements. Nielsen indicated that as the company continues to grow, investments in manufacturing infrastructure position Cirrus to meet customer demand while maintaining high standards of quality and safety.
Photo Credit: Cirrus Aircraft
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