This article is based on an official press release from Applied Aerospace & Defense.

Applied Aerospace and PCX Aerosystems Merge to Create Defense Hardware Giant

On December 3, 2025, Applied Aerospace and PCX Aerosystems announced their formal merger, establishing a new unified entity named Applied Aerospace & Defense. The consolidation brings together two significant portfolio companies of Greenbriar Equity Group, creating a large-scale supplier dedicated to critical hardware for the aerospace, space, and defense sectors.

According to the official announcement, the newly formed company will operate with a workforce of over 1,300 employees and a manufacturing footprint spanning 1.3 million square feet across nine locations. The mergers is designed to integrate the specialized composite capabilities of Applied Aerospace with the precision metal machining expertise of PCX Aerosystems, offering a “one-stop” hardware solution for major industry primes.

Trip Ferguson, formerly the Chief Operating Officer at BlueHalo, has been appointed as the Chief Executive Officer of the combined organization. The company will maintain a dual-hub operational structure, keeping major campuses in Stockton, California, and Newington, Connecticut.

Strategic Rationale: Combining Composites and Metals

The merger addresses a growing demand in the defense industrial base for suppliers capable of delivering complex, hybrid hardware solutions. By uniting these two organizations, Applied Aerospace & Defense aims to bridge the gap between advanced composite manufacturing and high-precision metallurgy.

Complementary Capabilities

Prior to the merger, the two companies held distinct but complementary market positions:

• Applied Aerospace (Stockton, CA): Known for large-scale complex composite and metal-bonded structures, including satellite bus structures, solar arrays, and radomes. Their recent acquisitions of Innovative Composite Engineering (ICE) and NeXolve further expanded their reach into space materials.
• PCX Aerosystems (Newington, CT): Specialized in flight-critical assemblies and precision machining, producing components such as rotor-heads, landing gear, and transmission assemblies for rotorcraft and fixed-wing platforms.

The combined entity is positioned to serve a wide range of sectors, including space exploration (launch vehicles and satellites), defense (missile systems and military aircraft), and commercial aviation.

Leadership and Operational Footprint

Trip Ferguson takes the helm as CEO, bringing extensive experience from the defense technology sector. A U.S. Marine Corps veteran, Ferguson previously managed operations at BlueHalo, a company known for its rapid growth in the defense space. In a statement regarding the merger, Ferguson emphasized the company’s commitment to heritage and agility.

“The new Applied Aerospace & Defense is forged in heritage, trusted in action, driven by mission, and engineered for agility. Our blue-chip customers and partners can expect the same experienced team, commitment to quality, and precision hardware… that they have come to trust.”

, Trip Ferguson, CEO of Applied Aerospace & Defense

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The company’s operational strategy involves maintaining its legacy headquarters in both California and Connecticut, ensuring continuity for existing programs while leveraging a footprint that now extends across five states, including Washington, Alabama, and Massachusetts.

AirPro News Analysis

This merger reflects a broader trend of consolidation within the aerospace supply chain, particularly among private equity-backed firms. Greenbriar Equity Group has effectively built a platform capable of competing for larger “programs of record” by combining niche specialists into a single, more robust entity.

For Tier 1 primes like Boeing, Lockheed Martin, and Northrop Grumman, managing a fragmented supply chain has become increasingly difficult amidst global disruptions. A supplier that can handle both the composite airframe structures and the metallic landing gear or propulsion components offers significant logistical advantages. We anticipate that Applied Aerospace & Defense will leverage this scale to bid on more complex, integrated sub-assemblies rather than just individual parts, positioning itself as a critical tier-1.5 supplier in the defense industrial base.

Sources

Sources: PR Newswire (Official Press Release)

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

Leonardo and 2Excel Aviation Awarded RAeS Bronze Medal for Excalibur Flight Test Aircraft

Leonardo and 2Excel Aviation have been jointly awarded the Royal Aeronautical Society (RAeS) Team Bronze Medal, a prestigious accolade recognizing their rapid engineering achievements on the Excalibur Flight Test Aircraft (FTA). Announced on December 2, 2025, the award highlights the successful transformation of a commercial Boeing 757 into a sophisticated “flying laboratory” designed to support the Global Combat Air Programme (GCAP).

The Excalibur project represents a critical component of the UK’s strategy to develop a sixth-generation combat aircraft, often referred to as Tempest. According to the official announcement from Leonardo, the RAeS medal specifically honors the “extraordinary efforts,” “pace,” and “agility” demonstrated by the joint team in modifying the airframe to host complex military avionics.

This recognition comes shortly after the team successfully completed the first phase of flight trials, which validated the aerodynamic stability of the aircraft while carrying substantial external modifications.

Engineering a Sixth-Generation Testbed

The Excalibur FTA is a retired Boeing 757-200 commercial airliner that has been heavily modified to test the advanced technology required for future combat scenarios. The primary mission of the aircraft is to de-risk the development of the ISANKE & ICS (Integrated Sensing and Non-Kinetic Effects and Integrated Communications Systems) domain.

By utilizing a large commercial airframe, the engineering team can install and test heavy, power-intensive sensors, such as radar, electronic warfare suites, and communications nodes, in a live flight environment long before the actual GCAP fighter prototype takes to the skies. This approach allows for real-time data monitoring by scientists on board the aircraft.

Phase 1 Success and Modifications

According to the press release and project updates, the award follows the completion of Phase 1 flight trials. These trials focused on safety and aerodynamics, ensuring the aircraft could fly stable with significant structural additions. Key modifications tested during this phase include:

• Cheek Fairings: Large structures attached to the fuselage designed to house lateral sensor arrays.
• Ventral Pods: Underbelly housings for additional communications and sensor equipment.
• Nose Cone Architecture: Preparations for a fighter-jet style nose cone to accommodate the Multi-Function Radio Frequency System (MFRS).

Industry Collaboration and Agile Development

The Royal Aeronautical Society’s decision to award the Team Bronze Medal underscores the effectiveness of the partnership between a major defense prime, Leonardo, and a specialized aviation services SME, 2Excel Aviation. The collaboration is cited by the UK Ministry of Defence as a model for “agile” defense procurement, prioritizing speed and innovation over traditional, slower development cycles.

In the official release, executives from both companies emphasized the unique challenges posed by the program.

“This award from the Royal Aeronautical Society recognizes the extraordinary efforts of the team and acknowledges the significant contribution that their work is making to the UK’s future combat air capability. The success of Excalibur reflects the strong partnership between Leonardo and 2Excel. Together, we are helping the programme break new ground while demonstrating pace and agility to meet the ambitious timelines of GCAP.”

, Anthony Todd, Project Chief Engineer, Leonardo

Steve Riley, Executive Director of 2Excel Aviation, noted the historical significance of the engineering pace achieved by the team.

“This programme has presented challenges in the UK aerospace industry that have not been present for decades. The team has met them head-on… demonstrating unparalleled pace throughout.”

, Steve Riley, Executive Director, 2Excel Aviation

AirPro News Analysis

The awarding of the RAeS Bronze Medal to the Excalibur team highlights a pivotal shift in how next-generation air dominance platforms are developed. Historically, avionics testing often waited for the availability of a representative military airframe, which could delay systems integration by years. By repurposing a Boeing 757, the GCAP partners are effectively decoupling the sensor development timeline from the airframe development timeline.

We observe that this “digital-first” and “test-early” methodology is essential for meeting the aggressive 2035 service entry target for the Tempest fighter. The ability to fly live sensors in 2025 suggests that the UK and its partners (Italy and Japan) are prioritizing the maturity of the “brain” of the aircraft, the ISANKE & ICS, just as much as the stealth characteristics of the airframe itself.

Frequently Asked Questions

What is the Excalibur Flight Test Aircraft?

Excalibur is a modified Boeing 757-200 used as a flying laboratory to test sensors and communications technology for the Global Combat Air Programme (GCAP).

What is the Royal Aeronautical Society Bronze Medal?

It is an award recognizing significant contributions to the advancement of aerospace art, science, and engineering, often highlighting team achievements in innovation.

When will the GCAP fighter enter service?

The Global Combat Air Programme aims to deliver a sixth-generation combat aircraft for service entry by 2035.

Sources

Leonardo

This article is based on an official press release from the Arab Organization for Industrialization (AOI). See the original release for full details.

Egypt Enters Global Supply Chain for Rafale Fighter Jets with New Manufacturing Deal

In a significant development for the Egyptian defense industry, the Arab Organization for Industrialization (AOI) has signed a new industrial cooperation contract with French aerospace giant Dassault Aviation. The agreement, finalized during the Egypt Defence Expo (EDEX) 2025, designates the AOI’s Helwan Military-Aircraft Factory as a certified partner in the global supply chain for the Rafale fighter jet.

According to the official press release from the AOI, the contract was signed in the presence of Lieutenant General Engineer Mokhtar Abdel Latif, Chairman of the AOI, and H.E. Eric Chevallier, the French Ambassador to Cairo. This deal marks a pivotal shift in the relationship between Egypt and Dassault, moving from a traditional buyer-seller dynamic to a strategic manufacturing partnership.

Under the terms of the agreement, Egyptian facilities will, for the first time, manufacture wing components for the Rafale aircraft. This step aligns with Egypt’s broader “Vision 2030” strategy to localize advanced defense technology and reduce reliance on foreign imports.

Helwan Aircraft Factory to Lead Production

The core of the agreement focuses on the Helwan Aircraft Factory, which has now been accredited to meet Dassault Aviation’s rigorous quality standards. The AOI statement confirms that the factory will produce specific wing parts for the Rafale, adhering to “Fourth Industrial Revolution” manufacturing standards. This ensures that components produced in Cairo are compatible with Dassault’s global requirements and can be integrated into aircraft destined for international markets.

Anne-Lise Dallut, General Manager of Dassault Aviation in Egypt, praised the capabilities of the Egyptian industrial base.

“The AOI’s factories have met Dassault’s rigorous quality and operational standards, serving as Egypt’s industrial backbone.”

This certification allows the AOI to act as a supply-chain hub, potentially exporting these locally manufactured parts back to France or to other nations operating the Rafale platform.

Strategic Context and French-Egyptian Cooperation

This contract builds upon years of deepening military and industrial ties between Cairo and Paris. Egypt currently operates one of the largest fleets of Rafale fighter jets outside of France, following major procurement deals signed in 2015 and 2021. The size of this fleet has provided a strong business case for localizing maintenance, repair, and overhaul (MRO) capabilities, as well as component manufacturing.

According to reporting by Ahram Online and Daily News Egypt, the partnership has evolved significantly over the last decade. Previous collaborations included the establishment of the AOI School for Applied Technology in Helwan, which trains Egyptian technicians using French curricula to ensure a skilled workforce capable of handling advanced aerospace technologies.

Expanding the Industrial Alliance

The Dassault agreement is part of a wider trend of French aerospace companies deepening their footprint in Egypt. As noted in reports from Sada Elbalad, the AOI also recently strengthened ties with Safran Aircraft Engines. In late 2024, the AOI Engine Factory was accredited as the sole international center for the overhaul of Larzac engines, which power the Alpha Jet aircraft. These simultaneous developments position Egypt as a regional hub for French defense exports to African and Arab markets.

Official Statements on the Partnership

During the signing ceremony at the Egypt International Exhibition Center, key officials highlighted the economic and strategic importance of the deal.

Lieutenant General Mokhtar Abdel Latif, Chairman of the AOI, emphasized that the agreement reinforces Egypt’s status as a pivotal regional hub for advanced manufacturing. In the official release, he stated that the AOI is committed to increasing local manufacturing content and attracting foreign investment by leveraging its advanced industrial base.

French Ambassador Eric Chevallier echoed these sentiments, noting the strategic nature of the collaboration.

“This partnership supports France’s goal of using Egypt as a hub to boost French exports to neighboring Arab and African nations.”

AirPro News Analysis

From Buyer to Maker: A Strategic Leap
The transition from purchasing military hardware to manufacturing components for that hardware represents a critical maturity milestone for Egypt’s defense sector. By securing a role in the supply chain of a flagship platform like the Rafale, the AOI is insulating itself against supply chain disruptions while simultaneously developing high-tech human capital.

Economic Implications
Beyond national security, this deal has significant economic potential. Integrating into a global supply chain allows Egypt to generate hard currency through exports. Furthermore, the adoption of “Fourth Industrial Revolution” standards at the Helwan factory will likely have positive spillover effects, raising industrial standards across other sectors of the Egyptian economy.

Sources

• Arab Organization for Industrialization (AOI)