MRO & Manufacturing
GE Aerospace Deploys 180 Engineers for Holiday Flight Operations
GE Aerospace positions 180 Field Service Engineers in 34 countries to prevent aircraft groundings and manage winter maintenance challenges during peak holiday travel.
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 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
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.
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.
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.
All Sleigh, No Delay: How Field Service Engineers Keep Holiday Fleets Airborne
The “Invisible Elves” of Aviation
Operational Wins: The GEnx-1B “Save”
Technical Challenges in Winter Operations
AirPro News Analysis: The Shift to Predictive Maintenance
Frequently Asked Questions
Sources
Photo Credit: GE Aerospace
MRO & Manufacturing
MAAS Aviation Renews easyJet Fleet Painting Contract with Lightweight Paint
MAAS Aviation will repaint easyJet’s Airbus A320 fleet using a lightweight paint to reduce weight, fuel consumption, and emissions, starting 2025.
This article is based on an official press release from MAAS Aviation.
MAAS Aviation, a global specialist in aircraft painting and exterior coatings, has officially announced the renewal of its multi-year partnership with European low-cost carrier easyJet. According to a statement released on December 9, 2025, the agreement secures MAAS Aviation as the designated partner for repainting easyJet’s entire Airbus A320 family fleet. The contract, which takes effect with the 2025/2026 painting season, underscores a deepening operational alignment between the two companies that began in 2020.
The renewal highlights a significant shift toward sustainability in Maintenance, Repair, and Overhaul (MRO) operations. Beyond standard livery application, the partnership focuses on the fleet-wide rollout of a new lightweight paint technology designed to reduce fuel burn and carbon emissions. All work is scheduled to take place at MAAS Aviation’s specialized facility at Maastricht Aachen Airport (MST) in the Netherlands.
Under the terms of the renewed contract, MAAS Aviation will handle the repainting of easyJet’s A319, A320, and A321 aircraft. The company stated that operations will be consolidated at their Maastricht facility, which features twin-bay paint shops capable of accommodating aircraft up to the size of a Boeing 767. These facilities are equipped with computerized building management systems and high-lux lighting to ensure Original Equipment Manufacturer (OEM) quality standards.
The partnership, which originated from a customer programme launched in late 2020, has evolved into a sole-supplier style arrangement for the A320 fleet at the Maastricht hub. Richard Marston, Chief Commercial Officer at MAAS Aviation, emphasized the importance of the long-term relationship in optimizing operational efficiency.
“We are proud to name easyJet as a long-term partner. The extension of their aircraft painting programme is testament to our streamlined processes which deliver aircraft finished to the highest OEM quality standards at the optimum TATs [Turnaround Times] this leading operator demands.”
Richard Marston, CCO, MAAS Aviation
A central component of the renewed agreement is the implementation of a “world-first” lightweight paint system developed in collaboration with Mankiewicz Aviation Coatings. According to the press release, easyJet became the first airline globally to trial this technology in January 2025, with MAAS Aviation serving as the MRO partner for the application.
The technical data provided by the companies indicates that the new coating system reduces the weight of a single aircraft by approximately 27 kilograms (59.5 lbs). While this reduction may seem minor on an individual unit basis, the cumulative effect across a high-frequency fleet is substantial. The reduction in weight leads to decreased drag and lower fuel consumption. Sophie Michelson, Aircraft Appearance Manager at easyJet, noted the dual focus on aesthetics and environmental impact:
“MAAS continue to demonstrate the highest standards of exterior paint application which has helped us to achieve industry leading exterior paint processes and finish. easyJet is committed to ensuring the highest standards of aircraft appearance, whilst continuously working on gains to reduce carbon emissions.”
Sophie Michelson, Aircraft Appearance Manager, easyJet
The companies have projected that once the rollout is completed across the fleet, targeted for 2029, the initiative will result in an annual reduction in fuel consumption of 1,296 tonnes. This equates to a reduction of over 4,000 tonnes of CO2 emissions per year, supporting easyJet’s broader “Net Zero” roadmap for 2050.
This contract renewal illustrates a growing trend in the aviation industry where MRO contracts are no longer defined solely by cost and turnaround time. Sustainability metrics are becoming a decisive factor in supplier selection. For low-cost carriers like easyJet, where margins are tight and fuel accounts for a massive portion of operating costs, a 27kg weight reduction per airframe represents a tangible efficiency gain. By integrating this requirement into their painting contract, easyJet effectively turns routine maintenance into a carbon-reduction strategy, setting a precedent for how airlines might leverage MRO partnerships to meet stringent environmental targets.
Scope of the Agreement and Operational Capabilities
Sustainability Through Technical Innovation
Projected Environmental Impact
AirPro News Analysis
Frequently Asked Questions
Sources
Photo Credit: MAAS Aviation
MRO & Manufacturing
Deutsche Aircraft Advances Leipzig FAL and D328eco Engine Delivery Q4 2025
Deutsche Aircraft completes Leipzig Final Assembly Line structure and receives first test engines for D328eco, targeting 2026 prototype flight and 2027 service entry.
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.
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.
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.
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: 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.
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.
The company also announced several key personnel changes aimed at preparing for operational readiness:
Deutsche Aircraft Reports Q4 2025 Milestones: Leipzig FAL Topping-Out and Engine Delivery
Industrialization at Leipzig/Halle Airport
Logistics Automation Partnership
D328eco Program and Engineering Updates
Global Market Engagement
AirPro News Analysis
Leadership Appointments
Frequently Asked Questions
Sources
Photo Credit: Deutsche Aircraft
MRO & Manufacturing
AerFin Acquires Third Ex-JAL Boeing 777-300ER in 2025 for Parts Inventory
AerFin secures a third Boeing 777-300ER from Japan Airlines in 2025 to boost global aftermarket inventory of airframe and GE90 engine components amid supply constraints.
This article is based on an official press release from AerFin.
On December 16, 2025, UK-based aviation aftermarket specialist AerFin announced the acquisition of a Boeing 777-300ER, marking its third purchase of this aircraft type from Japan Airlines (JAL) this year. The transaction underscores a strategic push to secure high-quality Used Serviceable Material (USM) for the global aftermarket, specifically targeting the airframe and GE90 engine components that remain in high demand.
According to the company’s official statement, this latest acquisition completes a significant year of investment in the widebody segment. The aircraft will be disassembled to harvest components, supporting a strained global supply chain where operators are extending the lives of existing fleets due to delays in new aircraft deliveries.
AerFin’s acquisition strategy in 2025 has heavily favored the Boeing 777-300ER platform, specifically assets previously operated by Japan Airlines. This consistent sourcing allows AerFin to offer a uniform standard of components to its customer base.
The timeline of these acquisitions highlights an aggressive expansion:
Auvinash Narayen, Chief Investment Officer at AerFin, emphasized the company’s commitment to this specific asset class in the press release:
“Purchasing another 777-300ER to our portfolio reflects our continued confidence in the asset and the operators who rely on it. Our global footprint and material stock provide the resilience our customers need to plan ahead with certainty.”
, Auvinash Narayen, CIO, AerFin
The decision to acquire and tear down these aircraft is driven by specific anomalies in the current aviation market. Industry analysis indicates that delays in the certification and delivery of the Boeing 777X have forced major international carriers to extend the operational service lives of their existing 777-300ER fleets.
As these older aircraft fly longer than originally planned, they require heavier maintenance and more frequent component replacements. Simultaneously, the production of new spare parts has faced global bottlenecks. Companies like AerFin bridge this gap by harvesting “Used Serviceable Material” (USM), certified parts removed from retired aircraft, which offers a faster and often more cost-effective solution than waiting for new OEM components. Securing these assets has become increasingly competitive. According to market intelligence from IBA and other industry observers referenced in sector reports, the market value for B777-300ERs and their engines has risen significantly throughout 2025. Some data suggests a jump of nearly 78% in half-life market values compared to previous years. AerFin’s ability to close three such deals in a single year suggests strong capital backing and effective relationship management with top-tier operators like JAL.
Why Japan Airlines? The “Hat-Trick” Strategy What is USM in aviation? Why is the GE90 engine significant? Where will the aircraft be disassembled?
AerFin Acquires Third Ex-JAL Boeing 777-300ER in 2025 to Boost Global Parts Inventory
Strategic Expansion of the 777 Portfolio
Market Context: The Demand for USM
Supply Chain Constraints
Rising Asset Values
AirPro News Analysis
From an editorial perspective, we note that AerFin’s specific focus on ex-Japan Airlines inventory is likely a calculated quality control measure. JAL is renowned in the industry for rigorous maintenance standards. Components harvested from their retired fleets typically command a premium in the aftermarket because they are less likely to suffer from unusual wear or deferred maintenance issues compared to assets from less regulated operators.
By securing three identical airframes from the same operator, AerFin achieves economies of scale in its teardown operations. It also allows them to offer “matched” sets of components to airlines, which simplifies integration for maintenance, repair, and overhaul (MRO) providers. This move positions AerFin not just as a parts trader, but as a critical infrastructure partner for airlines struggling to keep their long-haul fleets airborne amid OEMs delays.
Frequently Asked Questions
USM stands for Used Serviceable Material. It refers to aircraft parts that have been removed from a retired airframe or engine, inspected, repaired if necessary, and recertified for use on an active aircraft.
The Boeing 777-300ER is powered exclusively by the GE90-115B engine. It is one of the most powerful and complex commercial jet engines in service. As the 777 fleet ages, demand for GE90 spare parts (blades, disks, and accessories) has surged, making them highly valuable assets for teardown companies.
While the specific location for the December acquisition was not detailed in the immediate release, previous units acquired by AerFin in 2025 were disassembled in the United States (specifically New Mexico) to facilitate distribution across the Americas and Asia-Pacific regions.
Sources
Photo Credit: AerFin
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