MRO & Manufacturing
GKN Aerospace Advances UK Sustainable Additive Manufacturing
GKN Aerospace joins DECSAM, a £38M UK programme to enhance sustainable additive manufacturing and strengthen domestic aerospace supply chains.
A New Blueprint for UK Aerospace: GKN Aerospace Joins £38M Sustainable Manufacturing Initiative
The aerospace industry is at a critical juncture, navigating the dual pressures of technological advancement and a global mandate for sustainability. In a significant move to address these challenges head-on, GKN Aerospace has joined a landmark £38 million UK research and innovation programme known as DECSAM (Digitally Enabled Competitive & Sustainable Additive Manufacturing). This four-year initiative, led by Airbus, represents a concerted effort to redefine the future of aircraft component production, placing sustainability and digital integration at its core.
At the heart of this programme is Additive Manufacturing (AM), or 3D printing, a technology with the potential to build lighter, more complex, and resource-efficient parts. While methods like laser powder bed fusion (L-PBF) are already certified for flight, their widespread adoption has been hampered by productivity bottlenecks, a fragmented digital workflow, and a heavy reliance on international supply chains. The DECSAM programme is designed to dismantle these barriers, creating a cohesive, end-to-end AM ecosystem entirely within the United Kingdom.
By uniting 11 of the UK’s leading aerospace manufacturers, technology specialists, and research institutions, the project aims to forge a new path for the sector. The goal is not merely to improve existing processes but to build a scalable, cost-effective, and environmentally conscious manufacturing framework. This initiative is poised to strengthen the UK’s sovereign industrial capabilities, reduce the carbon footprint of aviation, and secure a competitive edge in the next generation of aerospace technology.
The DECSAM Programme: Forging a Sustainable and Sovereign Supply Chain
The DECSAM initiative is more than just a research project; it’s a strategic investment in the UK’s industrial future. With £38 million in funding from Innovate UK, the Aerospace Technology Institute (ATI), and the Department for Business and Trade, the programme is structured to deliver tangible results over its 48-month timeline, running from June 2024 to June 2028. Its mission is to create a digitally connected, highly productive, and sustainable domestic supply chain for aerospace-grade additive manufacturing.
A Vision for Integrated Manufacturing
The core vision of DECSAM is to tackle the primary obstacles limiting the scalability of AM in aerospace. The programme is structured around three key pillars: performance, productivity, and scalability. To enhance performance, the consortium will focus on developing new and improved metal alloys and physics-driven design methodologies that maximize the potential of 3D printing. This allows for the creation of components that are not only lighter but also stronger and more efficient than their traditionally manufactured counterparts.
On the productivity front, the project will explore the use of high-power lasers, advanced beam shaping, and sophisticated in-situ monitoring to speed up the printing process without compromising quality. By embedding real-time quality assurance into the production line, DECSAM aims to reduce post-processing and inspection times significantly. Finally, scalability will be achieved by developing a comprehensive “digital thread” that connects every stage of the process,from raw material sourcing to final part certification,and by designing automated, sustainable factory concepts ready for volume production.
A crucial element of this vision is strengthening the UK’s domestic capabilities. By “on-shoring” critical processes like material development and heat treatment, the programme aims to build a more resilient and self-sufficient UK aerospace sector. This reduces dependence on overseas suppliers, shortens lead times for critical components, and ensures that the UK can compete globally in the high-value manufacturing landscape.
The Power of a Unified Consortium
The strength of the DECSAM programme lies in its collaborative foundation. Led by Airbus, the initiative brings together a formidable team of 11 organizations, each a leader in its respective field. This consortium includes global giants like GKN Aerospace, AM technology pioneers like Renishaw plc, and standards bodies such as ASTM International UK. It also features innovative SMEs and vital research hubs, including Authentise Ltd, The Manufacturing Technology Centre, Additive Manufacturing Solutions Ltd, and the University of Sheffield, among others.
This collaborative approach ensures that expertise from every part of the AM value chain is integrated into the project. From developing sustainable feedstock and recycled powders to creating the software for in-process monitoring and establishing clear guidelines for part certification, the consortium covers all bases. This holistic strategy is designed to accelerate the adoption of AM by providing a proven, end-to-end solution that the wider industry can trust and implement.
“Additive manufacturing can unlock new efficiencies in aerospace, lowering costs, optimising material use, reducing weight, and consolidating complex assemblies into single parts. DECSAM unites a strong consortium to accelerate adoption in civil aerospace, aligning closely with the ATI’s additive manufacturing strategy to drive future economic growth and sustainability.” – Jacqueline Castle, Chief Technology Officer at the Aerospace Technology Institute (ATI)
GKN Aerospace’s Pivotal Role in Shaping Future Flight
As a global tier-one supplier, GKN Aerospace is uniquely positioned to drive the practical application of the technologies developed within the DECSAM programme. The company’s involvement is not just as a participant but as a key leader, tasked with integrating the project’s innovations into the next generation of aircraft engine products and championing the development of sustainable material solutions.
Leading Material and Process Innovation
GKN Aerospace’s primary role within the consortium is to bridge the gap between research and real-world application. The company will lead the charge in assessing and developing new material systems, with a strong emphasis on sustainable feedstock. This includes creating validated routes for using recycled and repurposed metal powders, a critical step toward establishing a circular economy within aerospace manufacturing and significantly reducing the industry’s environmental impact.
Furthermore, GKN Aerospace is responsible for developing advanced part-based simulation methods and coordinating studies on in-situ inspection and monitoring. These efforts are crucial for ensuring that additively manufactured parts meet the stringent safety and performance standards of the aerospace sector. By refining these digital tools, the company will help create a more predictable, reliable, and cost-effective production process, directly addressing the growing demand from engine customers for proven additive solutions.
This strategic focus aligns perfectly with GKN Aerospace’s long-term vision. The company sees additive manufacturing as a transformative force, capable of delivering profound environmental, performance, and supply chain advantages over traditional manufacturing methods. The DECSAM project provides the ideal platform to mature these capabilities and solidify the UK’s technology base for future production growth.
“The DECSAM Project strengthens GKN Aerospace’s broader additive manufacturing capabilities, delivering environmental, performance, and supply chain advantages over traditional material supply chains. With growing demand for additive solutions from all engine customers, this project enhances our UK technology base and positions us for future production growth.” – Sébastien Aknouche, SVP Material Solutions at GKN Aerospace
From Demonstrators to Next-Generation Aircraft
The ultimate goal of the DECSAM programme is to see its innovations take flight. The project’s outputs will include ground and flight-test demonstrators that showcase the cost and performance benefits of the newly developed AM processes on target aerospace parts. These demonstrators will serve as proof-of-concept for the entire integrated supply chain, building confidence and paving the way for wider adoption.
The applications are focused squarely on the future of aviation. The technologies developed will be critical for producing components for ultra-efficient wing and engine structures, helping to reduce the weight and fuel consumption of next-generation aircraft. Looking further ahead, the programme is also exploring applications for hydrogen-powered aviation, such as conformal heat exchangers and fuel-cell manifolds,complex parts that are ideally suited for additive manufacturing.
By focusing on these critical use cases, DECSAM is not just improving manufacturing for today’s aircraft but is actively enabling the designs of tomorrow. The initiative represents a foundational investment in the technologies that will underpin a more sustainable and competitive aerospace industry for decades to come.
Conclusion: A Strategic Leap Forward for UK Aerospace
The DECSAM programme is a clear and decisive step towards a more sustainable, competitive, and resilient UK aerospace sector. This £38 million initiative, powered by a consortium of industry leaders, is tackling the most significant barriers to the widespread adoption of additive manufacturing. By focusing on creating an integrated, digitally-enabled domestic supply chain, the project promises to reduce waste, lower carbon intensity, and enhance productivity across the board.
GKN Aerospace’s central role in this initiative underscores the company’s commitment to innovation and sustainability. By leading the development of new materials and integrating advanced AM technologies into future engine components, GKN is not only strengthening its own capabilities but is also helping to secure the UK’s position as a global leader in high-value manufacturing. The outcomes of DECSAM will resonate far beyond the project’s four-year timeline, setting new standards and creating a blueprint for the future of aircraft production.
FAQ
Question: What is the DECSAM programme?
Answer: DECSAM (Digitally Enabled Competitive & Sustainable Additive Manufacturing) is a £38 million, four-year UK research and innovation programme led by Airbus. Its goal is to advance sustainable additive manufacturing in the aerospace sector by creating a fully integrated, domestic supply chain.
Question: What is GKN Aerospace’s role in the project?
Answer: GKN Aerospace is a key partner responsible for integrating the programme’s technologies into future aircraft engine products. The company will also lead the development of new sustainable materials, including recycled powders, and advance simulation and in-situ inspection methods.
Question: What are the main goals of the DECSAM programme?
Answer: The primary goals are to make aerospace additive manufacturing more cost-effective, productive, and sustainable. It also aims to strengthen the UK’s manufacturing capabilities by “on-shoring” critical processes and building a resilient, end-to-end domestic supply chain for complex aerospace components.
Sources: GKN Aerospace
Photo Credit: GKN Aerospace
MRO & Manufacturing
FedEx Launches Dedicated Aircraft Engine Logistics Service
FedEx Logistics formalizes engine transport operations after moving hundreds of engines since June 2025 amid an $11B supply chain crisis.
FedEx Corp. has launched a dedicated engine logistics solution to transport main-deck aircraft engines and oversized aerospace components, targeting severe supply chain bottlenecks that are currently constraining global fleet availability.
Announced in a press release on October 29, 2026, the new service from FedEx Logistics formalizes operations that have already moved hundreds of engines since June 2025. The product launch arrives as airlines and maintenance providers grapple with extended lead times and parts shortages that cost the commercial aviation sector an estimated $11 billion in 2025.
Structuring the engine logistics service
The new logistics product features a dedicated team of aerospace experts managing main-deck engine quotations and overseeing shipment execution from origin to destination. According to the company, the service includes centralized oversight, regulatory compliance management, customs coordination, and a proprietary digital platform designed for quotation generation and documentation management.
FedEx Logistics President Marcus Balzereit noted that a delayed engine impacts flight schedules, aircraft availability, and maintenance commitments across the industry.
“With our own airline DNA, we understand firsthand the complexity and urgency behind keeping aircraft flying. Our solution brings together dedicated aerospace experts, digital innovation, and a proven global network to provide customers with the speed, visibility, and reliability they need to keep operations running efficiently,” Balzereit said.
The company operates the world’s largest Cargo aircraft airline, providing the infrastructure required to move oversized aerospace assets globally. Since June 2025, FedEx has transported hundreds of main-deck aircraft engines totaling thousands of tons, which served as the operational foundation for this formalized product launch.
A strategic shift toward premium aerospace freight
The formalization of the engine logistics product aligns with a broader strategic shift at FedEx Corp., which generates $90 billion in annual revenue and employs over 450,000 people worldwide. The logistics giant is increasingly targeting specialized, premium air freight volume to supplement its traditional parcel shipping business.
FedEx Corp. President and CEO Raj Subramaniam recently highlighted this transition, noting the rapid growth in specialized sectors.
“For example, we drove a 15-fold increase in aircraft engine moves and won new air freight business with an AI data center customer after more than a 40-year largely parcel-centric relationship,” Subramaniam said.
The commercial aerospace supply chain crisis
The aerospace sector is currently facing a historic supply chain crisis that has elevated the importance of rapid component transport. The commercial aircraft order backlog exceeds 17,000 units, representing nearly 60 percent of the active global fleet. This backlog has forced airlines to operate older aircraft longer than anticipated, driving up demand for maintenance and replacement parts.
Engine shortages remain a primary bottleneck. Extended lead times for critical components, particularly castings and forgings, have constrained both new engine production and existing engine repairs. The International Air Transport Association (IATA) estimated that supply chain disruptions cost airlines over $11 billion in 2025 alone.
The lack of spare engines and extended maintenance turnaround times have placed a premium on the rapid, reliable transport of critical aerospace assets. For airlines and maintenance, repair, and overhaul (MRO) providers, logistics has transformed from a routine procurement function into a strategic necessity to maximize fleet availability.
AirPro News analysis
The formalization of this engine logistics product highlights a structural shift in how airlines and MRO providers manage their assets. With spare engine pools depleted and new aircraft deliveries delayed by a 17,000-unit industry backlog, the financial penalty for an aircraft on ground (AOG) has never been higher. By pivoting its massive cargo network to prioritize high-value, oversized aerospace components, FedEx is capitalizing on a high-margin sector while addressing a critical bottleneck for its aviation peers.
This move also signals a broader logistics industry trend of diversifying away from traditional parcel volumes toward specialized, premium freight. FedEx is leveraging its own operational requirements as an airline to market a tested solution to other operators, effectively turning its internal supply chain expertise into a revenue-generating product during a period of unprecedented industry constraint.
Photo Credit: FedEx
MRO & Manufacturing
Boeing and Lufthansa Technik Renew Tailored Parts Package
Boeing and Lufthansa Technik extend their Tailored Parts Package for three years, covering 6,500-plus aircraft components.
The Boeing Company and Lufthansa Technik Group have renewed their Tailored Parts Package (TPP) agreement for an additional three years, securing manufacturer-managed supply chain execution for more than 6,500 commercial aircraft components.
The extension, announced on October 29, 2026, at the MRO Europe trade fair in Amsterdam, embeds Boeing’s original equipment manufacturer (OEM) logistics directly into the German maintenance provider’s global component pool. The agreement is designed to reduce sourcing complexity and provide cost predictability for airline customers operating Boeing fleets.
Integrating OEM logistics into third-party maintenance
The Tailored Parts Package is a Boeing commercial program structured to simplify parts procurement and inventory management for maintenance providers and operators. Under the terms of the agreement, customers commit to purchasing an agreed-upon group of parts during the contract term. In return, Boeing manages the supply chain execution for those specific components, providing predictable pricing and guaranteed lead times.
By having Boeing assume supply chain execution for the defined 6,500 parts, Lufthansa Technik integrates these capacities directly into its global component supply network. This direct connection to the manufacturer’s supply chain is intended to shorten procurement routes and prevent bottlenecks in critical aircraft components.
Thomas Boettger, Vice President Corporate Procurement at Lufthansa Technik, highlighted the operational necessity of the agreement in a press release issued by the company.
“Reliable access to material is a key factor in maintaining aircraft availability and operational efficiency. Through this renewed agreement with Boeing, we further strengthen our ability to provide customers worldwide with dependable parts support across all Boeing aircraft platforms. The combination of broad parts coverage and secure supply chain access creates tangible value for airlines in today’s demanding operating environment.”
William Ampofo, Senior Vice President of Parts & Distribution and Supply Chain at Boeing Global Services, noted that a stable aviation supply chain depends on experience, capability, and reach. He stated that the agreement brings those strengths together to help customers plan their parts needs with greater confidence.
Navigating aftermarket supply chain pressures
The commercial aviation aftermarket has operated in a highly constrained environment over recent years. The sector has been marked by global material shortages, persistent supplier delays, and rising logistics costs. The maintenance, repair, and overhaul (MRO) sector relies heavily on predictable supply chains to maintain aircraft availability and prevent aircraft on ground (AOG) situations.
Long-term supply contracts like the Tailored Parts Package are increasingly utilized by independent MRO providers to secure spare-parts availability. By routing manufacturer-guaranteed stockpiling directly into their own component pools, maintenance providers can insulate their airline customers from broader supply chain volatility and reduce unplanned downtime.
Corporate footprints in the global aftermarket
Headquartered in Hamburg, Germany, Lufthansa Technik operates as a manufacturer-independent provider of technical aircraft services. The company employs approximately 23,000 people across dozens of global locations. It holds international certifications as a maintenance, production, and design organization, offering MRO services for airframes, engines, components, and landing gears across commercial, VIP, and special mission aircraft.
Boeing Global Services (BGS) was formed in 2017 as Boeing’s dedicated services business unit. The division provides fleet sustainment, parts and distribution, digital capabilities, and MRO services. BGS employs roughly 18,900 direct employees worldwide, operates in 70 countries, and serves over 19,000 customers globally. The division is represented in commercial sales and marketing by Senior Vice President Dan Abraham.
AirPro News analysis
We view this three-year renewal as a clear indicator of how independent MRO providers are adapting to structural deficits in the aerospace supply chain. By outsourcing the logistics and stockpiling of 6,500 parts back to the original equipment manufacturer, Lufthansa Technik effectively hedges against unpredictable lead times and shifts a portion of its inventory risk to Boeing. For Boeing Global Services, locking in a major independent MRO provider for another three years guarantees predictable aftermarket revenue while tightening the integration between OEM parts distribution and third-party maintenance networks. This type of deep logistical integration is likely to become the standard defensive posture for major MROs as long as global material shortages persist.
Photo Credit: Lufthansa Technik
MRO & Manufacturing
EPCOR Secures APU Maintenance Deal for Airbus A330 MRTT Fleet
EPCOR and Airbus Defence and Space expand their MRO partnership to include APU maintenance for the global A330 MRTT military fleet.
EPCOR, a subsidiary of Air France Industries KLM Engineering & Maintenance (AFI KLM E&M), has secured a new agreement with Airbus Defence and Space to provide Auxiliary Power Unit (APU) maintenance support for the global Airbus A330 Multi Role Tanker Transport (MRTT) fleet.
Announced in a press release on October 28, 2026, the deal integrates EPCOR’s specialized APU capabilities into an established maintenance framework between AFI KLM E&M and Airbus. The partnership is designed to maintain high aircraft availability and operational readiness for military operators worldwide.
Expanding the MRO partnership
The new APU maintenance agreement builds upon an established maintenance, repair, and overhaul (MRO) relationship between AFI KLM E&M and Airbus Defence and Space. Prior to this expansion, the collaboration already included comprehensive engine and component maintenance for the MRTT fleet.
Felipe Steinmetz, Vice President of Procurement Services at Airbus Defence and Space, noted in the company statement that the manufacturer has developed a strong working relationship with AFI KLM E&M across several areas of aircraft maintenance.
“Bringing EPCOR into this cooperation allows us to build on that experience and further strengthen the support we provide to our A330 MRTT customers. Having partners who understand our operational requirements is important to us,” Steinmetz said.
Headquartered in Amsterdam, Schiphol-Rijk, EPCOR operates as a fully-owned subsidiary of the KLM Group. The facility provides component and APU maintenance services for more than 90 airlines globally. The Airbus agreement marks a deliberate step to apply that commercial aviation expertise to the defense sector.
Rob van de Graaf, Commercial Director at EPCOR, stated that supporting the A330 MRTT fleet presents an important opportunity for the company to apply its APU maintenance expertise in a different operational environment.
“We understand the importance of reliable maintenance support for aircraft performing critical missions and look forward to contributing our capabilities to the continued cooperation with Airbus Defence and Space,” van de Graaf said.
The A330 MRTT market footprint
The Airbus A330 MRTT is a military derivative of the commercial A330 wide-body airliner. The platform is designed to simultaneously perform air-to-air refueling, troop transport, cargo delivery, and medical evacuation without requiring physical reconfiguration between missions.
According to Airbus data from mid-2026, the A330 MRTT dominates the global aerial refueling market outside the United States, holding an estimated 90 percent market share. The program has secured 91 total orders and completed 67 deliveries.
The aircraft is currently operated by 17 nations. The global user base includes Australia, France, the United Kingdom, Saudi Arabia, Singapore, South Korea, and the NATO Multinational MRTT Fleet (MMF).
European reliance on the platform continues to grow. On August 25, 2026, Spain’s Council of Ministers authorized a €5.4 billion framework agreement for a joint acquisition with Poland of at least seven Airbus A330 MRTT aircraft, according to reporting by Defense News.
Airbus Defence and Space momentum
The expanded maintenance agreement coincides with a period of significant commercial growth for Airbus’s military division. On October 28, 2026, Airbus reported its financial results for the first nine months of the year, highlighting strong commercial momentum in its Defence and Space sector.
The division reported an order intake value reaching €11.5 billion during the first nine months of 2026. This represents a substantial increase from the €6.8 billion recorded during the same period in 2025.
AirPro News analysis
We view the expansion of this agreement as a clear indicator of how aerospace original equipment manufacturers (OEMs) are increasingly leveraging commercial MRO infrastructure to support military derivatives. Because the A330 MRTT shares significant structural and systems commonality with the commercial A330 airliner, tapping into EPCOR’s existing APU expertise allows Airbus to offer military operators the scale, turnaround times, and supply chain efficiency typical of the commercial sector.
This strategy is particularly critical as the MRTT fleet grows and European nations increase defense spending and operational readiness requirements. By outsourcing specialized component maintenance to established commercial shops like EPCOR, Airbus Defence and Space can ensure higher fleet availability rates for its military customers without needing to duplicate global MRO infrastructure.
Photo Credit: Airbus
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