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

AkzoNobel Announces €50 Million Upgrade to US Aerospace Coatings Operations

AkzoNobel has officially announced a significant investments of €50 million (approximately $52–55 million) to modernize and expand its aerospace coatings capabilities in North America. According to the company’s announcement on December 18, 2025, the project will focus on upgrading its flagship manufacturing facility in Waukegan, Illinois, and establishing a new distribution center in Pleasant Prairie, Wisconsin.

This strategic move aims to increase production capacity and shorten lead times for airline and Maintenance, Repair, and Operations (MRO) customers. By enhancing its supply chain infrastructure, AkzoNobel intends to address the growing demand for air travel and the subsequent need for advanced aerospace coatings.

Strategic Expansion in Illinois and Wisconsin

The investment centers on the Waukegan facility, which currently serves as AkzoNobel’s largest aerospace coatings production site globally. The site employs approximately 200 people and houses a dedicated color center. According to the press release, the capital injection will fund the installation of new machinery and automated processes designed to handle larger batch sizes.

To further optimize operations, the company is relocating its warehousing and distribution activities to a new facility in Pleasant Prairie, Wisconsin. This relocation is intended to free up floor space at the Waukegan plant, allowing for a focus on complex, customized chemical manufacturing.

Patrick Bourguignon, Director of AkzoNobel’s Automotive and Specialty Coatings, emphasized the forward-looking nature of the investment:

“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… and we want to make sure our customers are able to meet that demand.”

Operational Efficiency and the “Rapid Service Unit”

A key component of the upgrade is the introduction of a “Rapid Service Unit” dedicated to faster turnaround times for the MRO market. The company states that the new infrastructure will include a “liquid pre-batch area” and “high-speed dissolvers” to accelerate production.

Martijn Arkesteijn, Global Operations Director for AkzoNobel Aerospace Coatings, noted that these improvements are designed to enhance flexibility for customers:

“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.”

AirPro News Analysis: The Competitive Landscape

While AkzoNobel’s announcement focuses on internal efficiency, this investment arrives during a period of intensified competition within the North American aerospace sector. Earlier in 2025, rival manufacturer PPG announced a massive $380 million investment to construct a new aerospace coatings plant in Shelby, North Carolina.

In our view, AkzoNobel’s strategy differs significantly from its competitor’s greenfield approach. Rather than building new capacity from scratch, AkzoNobel is executing a targeted upgrade of existing assets. This “efficiency war” suggests that the company is betting on agility and technology upgrades, specifically the ability to deliver custom colors and small batches quickly via its new Rapid Service Unit, rather than simply expanding raw volume output.

Sustainability and Technology Integration

The upgraded facilities are also aligned with the aviation industry’s push for decarbonization. AkzoNobel highlighted that the investment supports the production of its “Basecoat/Clearcoat” systems, which are lighter than traditional coatings. Reducing paint weight is a critical factor for airlines seeking to lower fuel consumption and carbon emissions.

Furthermore, the new automated processes are expected to reduce chemical waste and solvent use. The facility upgrades will likely support the increased production of chromate-free primers, meeting stricter regulatory requirements in both the United States and the European Union.

By localizing more storage and production capacity in North America, AkzoNobel also aims to bolster supply chain resilience, addressing vulnerabilities exposed during the post-pandemic aviation recovery.

Sources

• AkzoNobel Press Release

All Sleigh, No Delay: How Field Service Engineers Keep Holiday Fleets Airborne

While millions of travelers settle in for holiday downtime, the global aviation industry enters its most critical operational window. According to AAA projections, approximately 122.4 million Americans traveled 50 miles or more from home during the 2024-2025 holiday season, with air travel seeing a projected 2.3% increase in domestic flyers. Behind this surge lies a largely invisible workforce dedicated to preventing cancellations before they happen.

According to an official press release from GE Aerospace, the company deployed 180 Field Service Engineers (FSEs) to 34 countries specifically to support Airlines customers during this peak period. These engineers are “embedded” directly with airlines and airframers, working on tarmacs and in hangars to mitigate technical risks that could otherwise ground fleets during the busiest weeks of the year.

The “Invisible Elves” of Aviation

The role of an FSE goes beyond standard maintenance; it involves proactive problem-solving under strict time constraints. GE Aerospace describes these teams as being on the front lines, ensuring that both passenger jets and cargo freighters remain operational despite the strain of high-cycle usage and winter weather.

Jordan Mayes, a Regional Leader for GE Aerospace Commercial Field Service in Western Europe and Africa, highlighted the intensity of the holiday operational tempo in the company’s statement:

“The sense of urgency is more elevated than normal… And often there are fewer hands to do the work.”

, Jordan Mayes, GE Aerospace Regional Leader

This urgency is driven not just by passenger volume, but by a booming air cargo sector. Industry data indicates that air cargo volumes saw double-digit growth in late 2024, driven by e-commerce demands and shipping disruptions in the Red Sea. Stephane Petter, a Regional Leader for Central/Eastern Europe and Central Asia, noted that the stakes for cargo are often underestimated.

“An issue with a grounded or delayed passenger aircraft might delay 350 people. With a cargo plane, thousands of parcels might be delayed, so the downstream customer impact is potentially greater.”

, Stephane Petter, GE Aerospace Regional Leader

Operational Wins: The GEnx-1B “Save”

To illustrate the impact of embedded engineers, GE Aerospace shared a specific operational success story involving Alaa Ibrahim, the Middle East regional leader. His team was monitoring a Boeing 787 Dreamliner equipped with GEnx-1B engines.

The engineers identified a minor clamp repair that was necessary to keep the engine compliant. The engine was only four cycles (flights) away from a mandatory 500-cycle inspection limit. If the limit was reached without the repair, the aircraft would be grounded, a disastrous outcome during peak holiday scheduling.

Instead of waiting for a forced grounding, Ibrahim’s team identified a six-hour window in the aircraft’s schedule. They performed the inspection and repair proactively, ensuring the aircraft remained available for service without disrupting the airline’s timetable.

Technical Challenges in Winter Operations

Beyond scheduling pressures, FSEs must contend with the physical realities of winter aviation. Industry reports highlight that “cold soak”, where an aircraft sits in freezing temperatures for extended periods, presents unique mechanical challenges. Oil can thicken, and seals can shrink or become brittle.

According to technical data regarding modern engines like the CFM LEAP, specific warm-up protocols are required to thermally stabilize the engine before takeoff power is applied. Maintenance teams often switch to lower-viscosity fluids and rigorously check breather tubes for ice accumulation. If a breather tube freezes due to condensation, it can pressurize the engine and cause seal failures.

AirPro News Analysis: The Shift to Predictive Maintenance

The deployment of these 180 engineers highlights a broader shift in aviation maintenance from reactive repairs to predictive intervention. By utilizing digital tools that monitor engine health in real-time, often referred to as “Flight Deck” principles, engineers can detect vibration trends or temperature spikes before they trigger a cockpit warning.

We observe that this strategy is particularly vital during the holidays. When load factors are near 100%, airlines have zero spare aircraft to absorb a cancellation. The ability of FSEs to turn a potential “aircraft on ground” (AOG) event into a scheduled maintenance task during a layover is the difference between a smooth operation and a headline-making travel meltdown.

Frequently Asked Questions

What is a Field Service Engineer (FSE)?

An FSE is a technical expert from an engine manufacturer (like GE Aerospace) who is embedded with airline customers to provide on-site support, troubleshooting, and maintenance advice.

How many engineers did GE Aerospace deploy for the holidays?

According to their press release, 180 FSEs were deployed across 34 countries specifically for the holiday rush.

Why is winter difficult for aircraft engines?

Extreme cold can affect oil viscosity and cause seals to shrink. Engineers must also manage de-icing procedures to prevent engines from ingesting ice, which can damage fan blades.

Sources

• This article is based on an official press release from GE Aerospace and includes additional industry context from AAA and aviation sector reports.

Deutsche Aircraft Reports Q4 2025 Milestones: Leipzig FAL Topping-Out and Engine Delivery

Deutsche Aircraft has released its Q4 2025 Quarterly Newsletter, outlining significant industrial and program advancements as the company pivots toward heavy industrialization and testing in 2026. According to the update released on December 17, 2025, the manufacturer has achieved key structural milestones at its Leipzig facility and received the first engines for its D328eco test program.

The newsletter highlights a transition from design phases to physical infrastructure and hardware integration. With the structural shell of the Final Assembly Line (FAL) complete and the supply chain delivering critical components, Deutsche Aircraft is positioning itself for the maiden flight of the D328eco in the coming year.

Industrialization at Leipzig/Halle Airport

A central focus of the Q4 update is the progress at the new Final Assembly Line (FAL) in Leipzig. On November 14, 2025, the company celebrated the “Richtfest”, or topping-out ceremony, marking the completion of the facility’s structural shell. This site is designated as the production hub for the 40-seat D328eco turboprop.

According to Deutsche Aircraft, the building handover is scheduled for the end of 2025, after which the installation of production equipment will commence. The facility represents an investment of approximately €100 million and is designed to support a production rate of up to 48 aircraft per year once fully operational.

Logistics Automation Partnership

To support the ramp-up, Deutsche Aircraft announced a strategic partnership with Jungheinrich to implement an automated logistics center within the FAL. The manufacturer states that this collaboration will introduce advanced storage solutions, including a “PowerCube” system and an automated narrow-aisle warehouse (AutoVNA). These systems are intended to maximize operational efficiency while aligning with the company’s carbon-neutral production goals.

D328eco Program and Engineering Updates

Beyond infrastructure, the newsletter detailed critical hardware arrivals. On November 17, 2025, Deutsche Aircraft took delivery of the first PW127XT-S developmental engines from Pratt & Whitney Canada. These engines are slated for installation on the TAC 1 (Test Aircraft 1), a crucial step toward ground runs and the prototype’s first flight, which is scheduled for 2026.

To bolster its engineering capabilities during the certification phase, the company has also formalized agreements with two major partners:

• Akkodis: Appointed as a Tier-1 supplier to assist with systems development, integration, and certification.
• Expleo: Signed a cooperation agreement to provide supplementary engineering services and reinforce the supply chain.

Global Market Engagement

Throughout the fourth quarter, Deutsche Aircraft intensified its marketing efforts in key regions requiring regional connectivity. On November 5, 2025, the company hosted the “Wings of Opportunity” summit in New Delhi. In collaboration with the Aerospace India Association, Cyient, and Dynamatic Technologies, the manufacturer pitched the D328eco as a solution for India’s UDAN regional connectivity scheme. The aircraft’s performance in hot-and-high conditions was highlighted as a key differentiator for serving Tier-2 and Tier-3 cities.

Simultaneously, the aircraft was presented at the ATAC Conference & Tradeshow in Canada, targeting operators who provide essential links to remote communities.

AirPro News Analysis

While the Q4 2025 newsletter emphasizes immediate industrial achievements, industry context remains vital for understanding the program’s broader trajectory. In mid-2025, Deutsche Aircraft revised the Entry into Service (EIS) target for the D328eco to Q4 2027, a shift from earlier 2026 projections. This adjustment was attributed to regulatory certification changes and global supply chain pressures.

The arrival of the PW127XT-S engines and the completion of the Leipzig facility shell are necessary prerequisites to meeting this revised timeline. The upcoming year, 2026, will be a stress test for the program as it moves from static completion to dynamic flight testing with the TAC 1 prototype.

Leadership Appointments

The company also announced several key personnel changes aimed at preparing for operational readiness:

• Alexander Tesch has been appointed VP of Customer Support & Service.
• Ernst-Georg Schröder takes the role of Final Assembly Line Manager to oversee the Leipzig ramp-up.
• Florian Luithlen has been promoted to Director of Training, focusing on simulator solutions.

Frequently Asked Questions

When is the D328eco expected to enter service?

Current targets place the Entry into Service (EIS) in Q4 2027.

What is the D328eco?

It is a 40-seat regional turboprop based on the legacy Dornier 328, featuring new Pratt & Whitney PW127XT-S engines, a Garmin G5000 Prime flight deck, and a stretched fuselage.

Where will the aircraft be built?

The aircraft will be assembled at a new Final Assembly Line (FAL) at Leipzig/Halle Airport in Germany.

Sources

• Deutsche Aircraft