MRO & Manufacturing
Bharat Forge Expands Aerospace Manufacturing with New Ring Mill
Bharat Forge to open a ring mill in 2026 for aerospace components, partnering with Pratt & Whitney Canada, supporting India’s aerospace growth.
Bharat Forge’s Strategic Expansion into Aerospace Manufacturing
Bharat Forge Ltd., a global leader in advanced forging and precision engineering, has announced the establishment of a state-of-the-art ring mill dedicated to aerospace applications. The facility, expected to be operational by 2026, will produce high-performance components for aero-engine applications, marking a pivotal step in India’s ambitions to become a global aerospace manufacturing hub.
This development follows a strategic partnership with Pratt & Whitney Canada, a move that not only strengthens Bharat Forge’s international presence but also aligns with national initiatives like Make in India and Atmanirbhar Bharat. The ring mill will integrate cutting-edge technologies, adhering to stringent global standards for quality and traceability, positioning India as a credible player in the global aerospace supply chain.
As global aerospace markets seek diversified and resilient supply chains, Bharat Forge’s investment signals a shift in manufacturing capabilities from traditional centers to emerging economies. This article explores the strategic, technological, and economic implications of Bharat Forge’s aerospace expansion, grounded in verified data and industry insights.
Corporate Background and Evolution of Bharat Forge
Founded in 1961 by Nilkanthrao A. Kalyani in Pune, Maharashtra, Bharat Forge has grown into the flagship company of the Kalyani Group. Under the leadership of Baba Kalyani, the company has evolved from a domestic forging unit into a multinational engineering powerhouse with a presence in multiple sectors including automotive, defense, oil and gas, and now aerospace.
Key milestones in the company’s history include its expansion into global markets in the early 1990s and major investments in forging technology throughout the 2000s. These included the installation of high-capacity press lines and the establishment of advanced machining facilities, which laid the groundwork for its current capabilities in precision engineering.
Today, Bharat Forge operates 18 manufacturing facilities across five countries and boasts an annual forging capacity of over 770,000 tons. Its financial performance in FY 2022-23 includes consolidated revenues of ₹16,817 crores (approximately $2.03 billion), with an EBITDA margin of 21.7%, figures that underscore its robust operational health and capacity for strategic investments.
Strategic Importance of the Ring Mill
The announcement of the new ring mill on July 30, 2025, marks a significant diversification into aerospace manufacturing. The facility will be located in Baramati, Maharashtra, leveraging existing infrastructure and workforce expertise. It aims to support both domestic and international aerospace programs, focusing on aero-engine components that demand high precision and performance.
According to Amit Kalyani, Vice-Chairman and JMD of Bharat Forge, the partnership with Pratt & Whitney Canada “reinforces our commitment to the global aerospace ecosystem and advances India’s manufacturing capabilities in high-value aerospace components.” This strategic alignment with a major aerospace OEM provides Bharat Forge with access to global best practices and quality standards.
Frederic Lefebvre, Vice President of Supply Chain at Pratt & Whitney Canada, emphasized the importance of the partnerships in building a resilient global supply chain and enhancing India’s aerospace ecosystem. With over 800 employees in India, Pratt & Whitney has a longstanding presence in the country, further validating Bharat Forge’s role as a trusted partner.
“This underscores our commitment to building a resilient global supply chain and advancing India’s aerospace ecosystem.”, Frederic Lefebvre, Pratt & Whitney Canada
Ring Rolling Technology and Aerospace Applications
Ring rolling is a critical process in aerospace manufacturing, used to produce seamless, high-strength components such as turbine rings and structural elements. The technique involves the plastic deformation of heated metal rings, resulting in components with superior mechanical properties and dimensional accuracy.
Modern ring rolling systems employ CNC controls, temperature and pressure sensors, and automated feeding mechanisms. These capabilities ensure tight tolerances and repeatability, essential for aerospace applications where failure is not an option. The process also allows for material versatility, accommodating alloys like titanium and nickel-based superalloys commonly used in jet engines.
Seamless rolled rings offer several advantages over cast or welded alternatives. They maintain structural integrity under high temperatures, reduce material waste, and lower machining costs due to their near-net shape. These factors make them ideal for aerospace use, where performance, reliability, and cost-efficiency are paramount.
Global Aerospace Forging Market Dynamics
The global aerospace forging market is poised for significant growth. In 2024, its size was estimated at USD 26.3 billion, with projections reaching USD 36.0 billion by 2030. Other forecasts suggest even higher growth, with some estimates pointing to a USD 99.1 billion market by 2037. This expansion is fueled by rising demand for lightweight, durable components and advancements in materials and forging technologies.
The commercial-aircraft segment dominates the market, driven by increasing air travel and demand for fuel-efficient planes. Military aviation is also a key growth area, with a focus on high-performance forged components for next-generation aircraft. Materials like titanium and aluminum alloys are in high demand due to their strength-to-weight ratios.
India, with its growing engineering talent pool and supportive government policies, is well-positioned to capitalize on this trend. The country’s share in global aerospace manufacturing is expected to rise, especially as OEMs diversify supply chains in response to geopolitical and logistical challenges.
India’s Aerospace Vision and Policy Support
India’s aerospace ambitions are backed by national initiatives such as Make in India and Atmanirbhar Bharat. These programs aim to increase domestic manufacturing and reduce reliance on imports, particularly in strategic sectors like aerospace and defense. The Ministry of Defence has set a target of USD 26 billion in aerospace and defense output by 2025.
Prime Minister Narendra Modi has also identified Maintenance, Repair, and Overhaul (MRO) services as a sunrise sector, with plans to develop a USD 4 billion MRO hub by 2030. These initiatives create a conducive environment for companies like Bharat Forge to invest in high-value manufacturing capabilities.
Public-private partnerships are central to this strategy. Companies such as Tata Advanced Systems and Hindustan Aeronautics Ltd. have already partnered with global OEMs like Boeing and Airbus. Bharat Forge’s ring mill adds to this ecosystem, bolstering India’s credibility as a destination for aerospace manufacturing.
Conclusion
Bharat Forge’s establishment of a ring mill for aerospace applications is a strategic move that aligns with both corporate growth objectives and national policy goals. The facility will enhance India’s position in the global aerospace supply chain while providing Bharat Forge with access to high-margin, technology-intensive markets.
As the facility becomes operational in 2026, it will serve as a testament to India’s evolving manufacturing capabilities. The project exemplifies how strategic partnerships, technological investments, and policy alignment can drive industrial transformation. Bharat Forge’s initiative could pave the way for further advancements in India’s aerospace sector, fostering innovation, job creation, and economic growth.
FAQ
What is the purpose of Bharat Forge’s new ring mill?
The ring mill will manufacture high-performance aerospace components, particularly for aero-engine applications, using advanced ring rolling technology.
When will the ring mill be operational?
The facility is expected to be operational by 2026.
Who is Bharat Forge partnering with for this project?
Bharat Forge has signed a strategic partnership with Pratt & Whitney Canada for the supply of aerospace components.
How does this project support India’s aerospace ambitions?
The project aligns with national initiatives like Make in India and Atmanirbhar Bharat, contributing to India’s goal of becoming a global aerospace manufacturing hub.
Sources:
Bharat Forge Ltd.,
Pratt & Whitney Canada,
MarketsandMarkets,
Business Standard,
LiveMint,
IATA,
Make in India,
Ministry of Defence, India
Photo Credit: Pune Bharat Forge Ltd
MRO & Manufacturing
Pratt & Whitney Canada Invests $275M CAD in Longueuil Plant
Pratt & Whitney Canada commits $275M CAD to automate its Longueuil facility, backed by federal and Quebec government support.
Pratt & Whitney Canada will inject $275 million CAD into its Longueuil manufacturing facility to integrate automated production lines and advanced digital processes, securing 650 jobs in the Quebec aerospace sector.
Announced on July 21, 2026, during the Farnborough International Airshow, the modernization project is backed by up to $34 million CAD from the Government of Canada, alongside support from the Quebec government. The investment targets the engine manufacturer’s global headquarters and largest manufacturing site, representing approximately $195.5 million USD in capital upgrades.
Upgrading industrial capacity for turbine production
The capital injection will fund the installation of modernized machinery and automated production lines at the Longueuil plant. Pratt & Whitney Canada, an RTX business, produces turbine engines for regional aircraft, business jets, general aviation, and rotorcraft platforms. By implementing advanced digital manufacturing processes, the company aims to increase production efficiency and precision to meet rising global demand for its propulsion systems.
In a press release detailing the investment, Pratt & Whitney Canada President Satheeshkumar Kumarasingam stated the upgrades will strengthen industrial capacity and enable the manufacturer to better support its customers.
“It also reinforces our longstanding role as a pillar of the Québec aerospace ecosystem and a major contributor to Canadian aviation,” Kumarasingam said.
Federal and provincial government support
The modernization effort is a joint public-private initiative. Innovation, Science and Economic Development Canada (ISED) is providing up to $34 million CAD through the federal Strategic Response Fund. The Ministère de l’Économie, de l’Innovation et de l’Énergie du Québec is also supporting the project, though specific provincial funding figures were not disclosed in the initial announcement.
The Longueuil facility currently employs nearly 4,500 people. According to the federal government, the financial engagement will directly maintain 650 jobs at the site. The announcement was coordinated with Mélanie Joly, Minister of Industry and Minister responsible for Canada Economic Development for Quebec Regions, highlighting the strategic importance of the aerospace sector to the regional economy.
AirPro News analysis
We view this $275 million CAD investment as a necessary step for Pratt & Whitney Canada to protect its manufacturing base against ongoing global supply chain pressures. By shifting toward automated production lines and digital processes, the engine manufacturer is positioning its legacy Longueuil facility to handle higher production rates with greater consistency. Announcing the capital upgrade at the Farnborough International Airshow serves a dual purpose: reassuring global airframers of the company’s capacity to deliver on engine backlogs while demonstrating the Canadian government’s willingness to subsidize critical aerospace infrastructure.
Sources: Pratt & Whitney Canada
Photo Credit: Pratt & Whitney Canada
MRO & Manufacturing
ExecuJet Belgium Earns EASA and FAA Approval for Falcon 6X
ExecuJet MRO Services Belgium secures EASA and FAA certification for Falcon 6X line and heavy maintenance plus AOG support.
ExecuJet MRO Services Belgium has secured regulatory approval from the European Union Aviation Safety Agency (EASA) and the Federal Aviation Administration (FAA) to perform line and heavy maintenance on the Dassault Falcon 6X.
Announced in a company press release on July 13, 2026, the dual certification allows the Brussels-based facility to service the growing global fleet of the 5,500-nautical-mile range business jet. The approval also expands the company’s Dassault MRO GoTeam capabilities to include aircraft-on-ground (AOG) support for the Falcon 6X.
Expanding global support for the Falcon 6X
In addition to EASA and FAA certification, the Brussels facility received maintenance approvals from the Civil Aviation Authority of Bermuda, the Department of Civil Aviation of Aruba, and the Office of the Director of Civil Aviation in Guernsey. These combined authorizations enable ExecuJet Maintenance, Repair, and Overhaul (MRO) Services to support a wide registry of international operators.
Matthijs Hutsebaut, Regional Vice President for Europe at ExecuJet MRO Services, highlighted the operational impact of the new certifications.
“EASA and FAA are the world’s two most internationally recognised civil aviation regulators. This approval is significant as it means we are now internationally certified to do line and heavy maintenance on all in-production Falcon aircraft types,” Hutsebaut stated.
According to the company, there are currently more than 30 Dassault Falcon 6X aircraft operating worldwide. Hutsebaut noted that demand for maintenance and support services is scaling alongside the active fleet. He added that the combination of original equipment manufacturer (OEM) expertise and AOG capabilities positions the facility to provide comprehensive support to operators.
Broader network growth and recent milestones
The Falcon 6X approval in Belgium follows a series of recent capability expansions across the ExecuJet MRO Services global network, which operates as a wholly-owned subsidiary of Dassault Aviation.
On June 11, 2026, the Belgium facility completed an extensive heavy maintenance project on a Dassault Falcon 7X. That project included an engine change, avionics upgrades, and the installation of a Starlink satellite communications system.
The company is also expanding its heavy maintenance footprint in the Asia-Pacific region. On June 3, 2026, ExecuJet MRO Services Australasia announced the expansion of its Dassault Falcon 7X heavy maintenance capabilities at its Sydney facility, with C-checks scheduled to commence in October 2026.
AirPro News analysis
As new clean-sheet aircraft designs like the Dassault Falcon 6X enter service and build flight hours, the availability of certified maintenance infrastructure becomes a critical factor for operator dispatch reliability. By securing EASA and FAA approvals at a major European hub, Dassault Aviation is leveraging its wholly-owned ExecuJet MRO Services subsidiary to capture aftermarket revenue while ensuring its newest flagship operators have immediate access to heavy maintenance and AOG recovery. We expect to see similar capability rollouts across other ExecuJet MRO Services regional hubs as the Falcon 6X fleet matures and approaches its first major scheduled maintenance intervals.
Photo Credit: ExecuJet MRO Services
MRO & Manufacturing
Jet Access Maintenance Becomes Starlink Dealer Amid Price Hike
Jet Access Maintenance joins the Starlink dealer network as SpaceX raises aviation hardware costs 38% and doubles its top-tier monthly plan.
Jet Access Maintenance has secured authorization as a Starlink dealer, expanding its in-flight connectivity upgrade offerings across three maintenance facilities on the same day SpaceX implemented a massive pricing restructure for its aviation internet service.
In a press release issued on July 7, 2026, the company confirmed it will now evaluate, acquire, install, and support Starlink Aviation solutions. The authorization allows Jet Access Maintenance to perform the upgrades at its Maintenance, Repair, and Overhaul (MRO) facilities in Indianapolis, Indiana; Nashville, Tennessee; and West Palm Beach, Florida.
Expanding MRO connectivity capabilities
The addition of Starlink hardware sales and activation support integrates into the company’s broader aircraft modernization initiatives. Installations will be completed by Federal Aviation Administration (FAA) certified technicians.
The MRO provider will handle ongoing maintenance, technical support, and integration with existing avionics systems for business aviation operators. Scott Dillon, President of Jet Access Maintenance, stated in the release that connectivity is an increasingly important part of the ownership and flight experience.
“By adding Starlink to our offering, we’re expanding the solutions available to our clients and helping them identify the connectivity platform that best supports their aircraft and mission requirements,” Dillon said.
SpaceX restructures Starlink Aviation pricing
The Jet Access Maintenance announcement coincides exactly with a major shift in Starlink’s business model. On July 7, 2026, SpaceX notified customers of a significant pricing restructure for its Starlink Business Aviation plans.
According to reporting by Aviation Week and Corporate Jet Investor, the top-tier Aviation Global Unlimited plan doubled in price from $10,000 to $20,000 per month. SpaceX also introduced a new mid-tier option, the Aviation Regional Unlimited plan, priced at $12,500 per month. This regional plan restricts unlimited data usage to a single continental region.
Hardware costs for business jets also saw a substantial increase. Holstein Aviation reported that the cost for Starlink Aviation hardware installation rose by approximately 38 percent, jumping from $145,000 to $200,000. Official Starlink Support documentation confirms these new rates take effect for existing customers on August 7, 2026.
AirPro News analysis
We note that the timing of this dealer authorization places Jet Access Maintenance in a unique position. The company is entering the Starlink dealer network just as the product undergoes its most significant pricing and tier-structure shift to date.
The 38 percent increase in hardware costs and the doubling of the global unlimited data plan alter the value proposition for mid-light jet operators. While Starlink remains a highly sought-after low-latency connectivity solution, the new $200,000 hardware baseline and $12,500 minimum monthly commitment will likely shift the primary upgrade market toward heavy jet and ultra-long-range aircraft operators. Jet Access Maintenance will need to navigate this new pricing reality as it pitches modernization initiatives to its existing client base.
Sources: Jet Access Maintenance, Aviation Week, Corporate Jet Investor, Starlink Support, Holstein Aviation
Photo Credit: Jet Access Maintenance
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