MRO & Manufacturing
Daher Wins 2026 JEC Award for Thermoplastic Wing Rib Innovation
Daher received the 2026 JEC Innovation Award for developing a thermoplastic wing rib that reduces weight, cost, and production time in aerospace manufacturing.
This article is based on an official press release from Daher.
On January 12, 2026, the French industrial conglomerate Daher was announced as the winner of the prestigious 2026 JEC Composites Innovation Award in the “Aerospace – Parts” category. The award recognizes the company’s development of a “Highly Loaded Thermoplastic Wing Rib,” a critical structural component designed to meet the rigorous demands of future single-aisle Commercial-Aircraft programs.
According to the company’s announcement, this innovation represents a significant leap forward in the application of thermoplastic composites. While previous applications were often limited to thinner, secondary parts, this project demonstrates the viability of thermoplastics for thick, primary aerostructures that must withstand heavy mechanical loads.
The award-winning component is a structural breakthrough for the aerospace industry. Traditionally, primary structures like wing ribs, which maintain the aerodynamic shape of the wing and transfer loads between the skin and spars, have been manufactured using aluminum or thermoset composites that require lengthy autoclave curing cycles.
Daher’s new rib is a thick laminate structure consisting of up to 64 plies, reaching a thickness of approximately 12mm. By successfully manufacturing a part of this density and complexity using thermoplastics, Daher has proven that the material can replace metal in the most demanding areas of an airframe.
The project was executed through a strategic consortium involving several key European partners, each contributing specialized expertise to the Manufacturing chain:
The success of the “Highly Loaded Thermoplastic Wing Rib” relies on the integration of two patented processes that streamline production and eliminate traditional manufacturing bottlenecks.
First, the rib utilizes Direct Stamping®, a Daher-patented process. According to the press release, this technique eliminates the intermediate “consolidation” step typically required between layering fibers (layup) and the stamping phase. By removing this step, the production cycle is significantly shortened, and energy consumption is reduced.
Second, the assembly utilizes Infrared (IR) Welding, a patent held by the Luxembourg Institute of Science and Technology (LIST). Instead of using heavy metal rivets or bolts to assemble the rib’s T-shaped profile, the partners used IR welding to create a continuous, integrated composite structure. This approach eliminates the weight of fasteners and improves the overall integrity of the part. “This JEC Award rewards our commitment to advancing composite technologies for aeronautics. We believe in it: by combining innovative materials and advanced processes, we demonstrate that it is possible to combine performance, competitiveness, and reduction of the carbon footprint.”
, Dominique Bailly, R&D Director at Daher
The shift to thermoplastics and the elimination of fasteners has yielded quantifiable performance improvements. Data provided by Daher highlights the following metrics for the new wing rib compared to traditional aluminum or bolted metal assemblies:
The significance of this award extends beyond a single component; it addresses the “holy grail” of next-generation aircraft manufacturing: rate. As Airbus and Boeing look toward successors for the A320 and 737 families, they face the requirement of producing wings at unprecedented rates, potentially 75 to 100 aircraft per month.
Traditional thermoset composites, while light, are chemically slow to cure, creating a bottleneck in the factory. Thermoplastics, which can be stamped, melted, and welded in minutes, are widely viewed as the necessary enabler for these high-rate programs. By demonstrating that thermoplastics can handle the structural loads of a primary wing rib, Daher is positioning itself as a critical supplier for the “Wing of Tomorrow.” Furthermore, the use of induction welding (seen in their 2025 Torsion Box project) and now IR welding suggests Daher is building a diverse toolkit of joining technologies to eliminate rivets entirely from future airframes.
Sources: Daher
Daher Wins 2026 JEC Innovation Award for Thermoplastic Wing Rib
Breaking Boundaries in Composite Manufacturing
Collaborative Development
Technical Innovations and Process Efficiency
Performance Metrics and Environmental Impact
AirPro News Analysis
Frequently Asked Questions
Photo Credit: Daher
MRO & Manufacturing
AkzoNobel Invests $58M to Modernize Waukegan Aerospace Plant
AkzoNobel commits $58 million to upgrade its Waukegan aerospace coatings facility, enhancing capacity and efficiency to meet rising air travel demand.
This article summarizes reporting by the Chicago Tribune and official announcements from AkzoNobel. This article summarizes publicly available elements and public remarks.
AkzoNobel has announced a significant capital injection of €50 million (approximately $58 million) into its Waukegan, Illinois, facility, solidifying the site’s status as the company’s largest aerospace coatings production plant in the world. According to reporting by the Chicago Tribune and official company statements released in early January 2026, the project aims to modernize manufacturing capabilities and expand capacity to meet surging global travel demand.
The investment involves a strategic reorganization of AkzoNobel’s North American footprint. While the Waukegan site will focus on intensified manufacturing, warehousing operations are set to relocate to a new facility in Pleasant Prairie, Wisconsin. This shift allows the company to repurpose existing storage space in Illinois for production lines, directly addressing the need for higher output.
The upgrade focuses on what AkzoNobel describes as “Industrial Excellence,” a program designed to streamline operations through advanced automation and improved workflow. The Waukegan facility, located at 1 East Water Street, currently spans 11 acres and employs approximately 200 people.
According to details shared in the company’s announcement, the modernization will be executed in two phases. The primary goal is to enhance supply chain resilience in North America, offering shorter lead times for airline and MRO (Maintenance, Repair, and Operations) customers.
The investment will fund the installation of state-of-the-art machinery intended to increase throughput and consistency. Key technical enhancements include:
The decision to expand comes as the aerospace industry prepares for a projected rise in global air travel. Airlines and manufacturers are increasingly requiring specialized coatings for both new aircraft deliveries and the maintenance of existing fleets. By moving finished goods storage to the new Wisconsin facility, AkzoNobel expects to significantly increase its production capacity for primers, basecoats, clearcoats, and custom colors.
Patrick Bourguignon, Director of AkzoNobel’s Automotive and Specialty Coatings business, emphasized the strategic necessity of the move in a press statement:
“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 over the next few years and we want to make sure our customers are able to meet that demand with aircraft of the highest quality.”
Beyond raw capacity, the upgrades are designed to offer greater flexibility in production batch sizes. Martijn Arkesteijn, Global Operations Director for AkzoNobel Aerospace Coatings, noted that the improvements would directly benefit customer timelines. “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.”
While the primary focus of the investment is operational efficiency, AkzoNobel has stated that the project aligns with its broader environmental goals. The company aims to reduce carbon emissions by 50% by 2030 (using a 2018 baseline) and transition toward 100% renewable electricity. The new equipment installed at the Waukegan plant is expected to reduce energy intensity per unit of production, supporting these corporate sustainability targets.
The separation of manufacturing and warehousing is a growing trend among industrial suppliers facing land constraints in established industrial zones. By decoupling storage from production, AkzoNobel effectively unlocks new square footage for value-added manufacturing without the need to acquire adjacent land, which can be difficult in developed areas like Waukegan. This move suggests a prioritization of speed and volume, critical factors as the aerospace supply chain continues to recover and expand post-pandemic.
Sources: Chicago Tribune, AkzoNobel Official Announcements
AkzoNobel Invests $58 Million to Modernize Waukegan Aerospace Hub
Scope of the Expansion
Technological Upgrades
Strategic Context and Market Demand
Operational Flexibility
Sustainability Targets
AirPro News Analysis
Sources
Photo Credit: AkzoNobel
MRO & Manufacturing
ASG Helicopter Services Launches Leonardo AW189 in Caspian Region
ASG Helicopter Services integrates the first Leonardo AW189 helicopter in the Caspian Sea region for offshore oil and gas support missions.
This article is based on an official press release from ASG Helicopter Services.
ASG Helicopter Services (ASG), a prominent aviation operator based in Azerbaijan, has officially integrated its first Leonardo AW189 helicopter into its fleet. The delivery, celebrated during a presentation on December 17, 2025, marks a significant operational milestone as the first aircraft of its type to enter service in the Caspian Sea region, covering Central Asia and the Caucasus.
According to the company’s announcement, this delivery is the first of two units ordered to support offshore oil and gas operations. The second unit is scheduled for delivery in early 2026. The acquisition was executed through a partnership involving ASG, the manufacturer Leonardo Helicopters, and Exclases Group, the exclusive distributor for Leonardo in the region.
The newly delivered AW189 has been supplied in a specialized offshore configuration designed to meet the rigorous demands of the energy sector. ASG Helicopter Services states that the aircraft is tailored for long-range transport and overwater safety, bridging the operational gap between the company’s medium-class AW139s and heavy-class Sikorsky S-92As.
The “super-medium” class helicopter features a maximum take-off weight (MTOW) of approximately 8.3 to 8.6 tonnes and is configured to carry 16 passengers plus two pilots. Key safety specifications highlighted in the release include a main gearbox capable of a 50-minute “run-dry” operation, exceeding standard certification requirements, and a Full Ice Protection System (FIPS) to manage the challenging winter conditions of the Caspian region.
ASG Helicopter Services indicated that the introduction of the AW189 is part of a broader strategy to modernize its fleet and enhance service offerings for major clients such as SOCAR, BP, and TOTAL. By adopting the super-medium platform, the operator aims to provide a more cost-efficient solution for missions that require significant range and payload but do not necessitate the full capacity of a heavy helicopter.
Azer Sultanov, Head of ASG Helicopter Services, emphasized the importance of this acquisition for the company’s future operations:
“Next-generation helicopters represent a significant new era for ASG Helicopter Services. The integration of the AW189 helicopter into our offshore operations strengthens our capability to meet the evolving needs of customers in the oil, gas, and energy sectors, while ensuring the highest standards of safety, reliability, and operational efficiency.”
The company confirmed that the aircraft has already received all necessary registration and airworthiness certificates from the Civil Aviation Authority of Azerbaijan. The arrival of the AW189 in the Caspian region reflects a wider global trend in the offshore energy sector: the shift toward “super-medium” rotorcraft. For years, the industry relied heavily on heavy helicopters for deep-water transport. However, volatility in oil prices and advancements in avionics have driven operators toward aircraft that offer near-heavy payload capabilities with the lower operating costs of a medium airframe.
By securing the first AW189 in the region, ASG positions itself as a technological leader in the Central Asian market. This move likely anticipates stricter safety standards from International Oil and Gas Producers (IOGP), which increasingly favor modern airframes equipped with advanced terrain awareness and run-dry capabilities. We expect this acquisition to place pressure on regional competitors to upgrade their legacy fleets to maintain contracts with international oil majors.
The AW189 is powered by two General Electric CT7-2E1 engines, providing the necessary power for long-range missions to remote rigs. According to manufacturer data referenced in the report, the aircraft includes a suite of advanced avionics designed to reduce pilot workload and enhance situational awareness.
ASG Helicopter Services, which already operates as an Authorized Service Center for Leonardo’s AW139 and AW109 models, will extend its maintenance capabilities to support the new AW189 fleet.
What is the primary role of the new AW189? How many passengers can it carry? When will the second unit arrive?
ASG Helicopters Services Introduces First Leonardo AW189 to Caspian Region
Operational Capabilities and Configuration
Strategic Fleet Modernization
AirPro News analysis
Technical Specifications and Safety
Frequently Asked Questions
The helicopter is configured for offshore transport, ferrying personnel and supplies to oil and gas platforms in the Caspian Sea.
In its current offshore configuration, the aircraft seats 16 passengers and 2 pilots.
ASG expects to take delivery of the second AW189 in early 2026.
Sources
Photo Credit: ASG Helicopter Services
MRO & Manufacturing
AAR Corp to Close Indianapolis Maintenance Facility Impacting 329 Jobs
AAR Corp. will close its Indianapolis maintenance hub by 2027, laying off 329 employees following its HAECO Americas acquisition.
This article summarizes reporting by IndyStar and official filings. The original report is paywalled; this article summarizes publicly available elements and public remarks.
AAR Corp. (NYSE: AIR) has confirmed plans to permanently shutter its airframe maintenance facility at the Indianapolis International Airport (IND), a move that will result in the layoff of approximately 329 employees. According to a Worker Adjustment and Retraining Notification (WARN) Act notice filed with the Indiana Department of Workforce Development on December 22, 2025, the closure is scheduled to take place in phases over the next year.
The decision marks the end of a two-decade era for the facility under AAR’s management. Reporting by IndyStar indicates that the closure aligns with the expiration of the company’s lease and follows a significant strategic shift in AAR’s North American operations. The shutdown process is set to begin on February 15, 2026, and is expected to conclude by February 28, 2027.
The closure of the Indianapolis site appears to be a direct consequence of AAR’s recent expansion efforts elsewhere. In November 2025, AAR finalized the acquisition of HAECO Americas for a reported $78 million. This transaction provided the aviation services company with two modern heavy maintenance facilities located in Greensboro, North Carolina, and Lake City, Florida.
According to industry analysis and financial reports, the HAECO acquisition included approximately $850 million in long-term contracts, effectively securing capacity at the newly acquired sites. Consequently, the Indianapolis facility, a legacy asset requiring a lease renewal, was deemed redundant within the optimized network.
The Indianapolis Maintenance Center, located at 2825 W. Perimeter Road, is a massive 1.6 million-square-foot complex originally constructed in the early 1990s. AAR leased approximately 367,000 square feet of this space. Reports suggest that the aging infrastructure of the facility, often described in local aviation circles as “legacy” compared to modern standards, played a role in the decision.
AAR’s lease with the Indianapolis Airport Authority (IAA) was approaching expiration. Rather than committing to a long-term renewal, the company signed a short-term extension through February 2027. This timeline mirrors the final closure date outlined in the WARN notice, signaling a deliberate exit Strategy rather than a sudden financial collapse.
The primary impact of this consolidation will be felt by the local workforce. The WARN notice specifies that 329 employees will be separated from the company starting in mid-February 2026. AAR has stated that all affected employees are receiving at least 60 days’ notice, complying with federal requirements. The Indiana Department of Workforce Development is expected to activate its “Rapid Response” team to assist displaced workers. This state-led initiative typically provides job placement assistance, resume workshops, and Training opportunities to help workers transition to new employment.
The Indianapolis Maintenance Center has a complex history tied to public investment. Originally built for United Airlines in 1994, the facility was supported by over $300 million in taxpayer incentives with the promise of thousands of jobs. However, United Airlines vacated the site in 2003 following bankruptcy proceedings.
AAR took over the facility in 2004, stabilizing the site and employing hundreds of mechanics for over 20 years. The upcoming departure leaves the Indianapolis Airport Authority with a significant vacancy, specifically 10 hangar bays, that has historically been difficult to fill.
Despite the closure, AAR Corp. remains in a strong financial position. Fiscal Year 2025 reports indicate a 20% revenue growth, reaching $2.8 billion. This growth has been driven largely by acquisitions and robust demand for aftermarket parts. The company’s stock performance has trended upward, with analysts interpreting the consolidation of operations into the HAECO facilities as a margin-positive move.
The closure of the Indianapolis facility underscores a broader trend in the MRO sector: the prioritization of owned, modern assets over leased legacy infrastructure. By acquiring HAECO, AAR not only gained capacity but also secured a workforce and facility footprint that likely offers better long-term economics than the aging Indianapolis site.
For the Indianapolis Airport Authority, this presents a familiar challenge. The facility was designed for a different era of aviation, where massive, single-tenant hubs were the norm. In today’s market, finding a single tenant to occupy such a vast space is increasingly difficult. We anticipate the IAA may need to subdivide the space or seek non-traditional tenants to utilize the hangars effectively once AAR departs in 2027.
When will the layoffs begin? Is AAR Corp. in financial trouble? What will happen to the facility?
AAR Corp. to Close Indianapolis Maintenance Hub, Impacting 329 Workers
Strategic Consolidation Following HAECO Acquisition
Facility Condition and Lease Timing
Impact on Workforce and Local Economy
Historical Context of the Site
Financial Health and Market Trends
AirPro News Analysis
Frequently Asked Questions
According to the WARN notice, the first separations are scheduled to begin on February 15, 2026.
No. Financial reports show AAR is growing, with a 20% revenue increase in FY2025. The closure is a strategic move to consolidate operations following the acquisition of HAECO Americas.
The facility will revert to the control of the Indianapolis Airport Authority after the lease expires in February 2027. The IAA has not yet announced specific plans for the site.
Sources
Photo Credit: AAR Corp
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