MRO & Manufacturing
DLR Tests Rotor Technology to Reduce Helicopter Noise and Vibration
DLR’s STAR project uses piezoceramic actuators to reduce helicopter noise by 7 dB and vibrations by 50% in wind tunnel tests.
This article is based on an official press release from the German Aerospace Center (DLR).
Researchers at the German Aerospace Center (DLR), in collaboration with a consortium of international aerospace agencies, have successfully demonstrated a new rotor technology capable of significantly reducing helicopter noise and vibration. The breakthrough, achieved under the Smart Twisting Active Rotor (STAR) project, utilizes “artificial muscles” to actively twist rotor blades during flight without the need for heavy mechanical components.
According to the DLR, wind tunnel tests conducted in late 2025 confirmed that the system reduces noise during the critical landing phase by up to 7 decibels (dB) and cuts hub vibrations by more than 50 percent. These results mark a significant step forward for rotorcraft engineering, particularly for the emerging Urban Air Mobility (UAM) sector where noise pollution is a primary barrier to adoption.
Traditional helicopter rotors rely on complex mechanical linkages, swashplates, and hydraulic systems to change blade pitch. While effective for basic flight control, these systems are often too slow or heavy to counteract the rapid, complex aerodynamic interactions that generate the characteristic “whop-whop” sound of a helicopter, known as Blade-Vortex Interaction (BVI).
The STAR project takes a fundamentally different approach. Instead of mechanical flaps, the rotor blades are equipped with piezoceramic actuators integrated directly into the blade skin. When an electrical voltage is applied, these actuators expand or contract, functioning like artificial muscles to twist the blade.
The DLR reports that this system allows for both static and dynamic twisting. Static twisting adjusts the blade for general flight regimes, such as hovering or cruising. However, the system’s true innovation lies in its dynamic capabilities. The actuators can twist the blades hundreds of times per second, allowing the rotor to adapt instantaneously to changing airflow and neutralize the aerodynamic shocks that cause noise and vibration.
“The special thing about this approach is that the active twisting of a rotor blade requires no mechanical components and is only minimally affected by the centrifugal forces acting on the rotor blades.”
, Berend Gerdes van der Wall, Project Manager at DLR Institute of Flight Systems
The technology was validated during a three-week campaign at the Large Low-Speed Facility (LLF) of the German-Dutch Wind Tunnels (DNW) in the Netherlands. The team utilized a four-meter diameter model rotor, a 40 percent scale model of a BO 105 helicopter rotor, to gather acoustic and aerodynamic data. Data collected during the tests revealed a noise reduction of up to 7 dB during descent. In acoustic terms, a reduction of this magnitude corresponds to cutting the perceived noise intensity by more than half for observers on the ground. This reduction is critical for operations over populated areas, where landing noise is often the most disruptive phase of flight.
In addition to acoustic benefits, the system demonstrated a massive improvement in ride quality. Vibrations acting on the rotor hub were reduced by over 50 percent. According to the project data, this reduction not only improves passenger comfort but also decreases mechanical stress on the aircraft, potentially extending the lifespan of critical components.
“The results show that efficiency increased while noise and vibration were significantly reduced. During the measurement campaign, we were able to successfully test our concept in a realistic environment.”
, Berend Gerdes van der Wall, DLR
While led by DLR, the STAR project represents a major global effort in aerospace research. The technology was developed and tested with contributions from several leading organizations, ensuring the data is validated across different engineering standards.
The consortium includes:
The success of the STAR project has implications far beyond traditional helicopters. As the aviation industry pivots toward eVTOL vehicles for air taxis, noise remains the single largest hurdle to regulations approval and public acceptance. A 7 dB reduction is not merely an incremental improvement; it could be the difference between a vertiport being approved in a city center or being pushed to the outskirts.
Furthermore, the elimination of mechanical parts in favor of solid-state piezoceramic actuators aligns with the industry’s push for lower maintenance costs. If this technology scales effectively from the 40 percent model to full-size aircraft, we expect to see “active twisting” blades become a standard feature in next-generation military and civilian rotorcraft.
What is the primary benefit of the STAR rotor system? How does the blade twist without mechanics? Who was involved in the testing?
DLR Successfully Tests “Artificial Muscles” to Slash Helicopters Noise and Vibration
The STAR Project: How Active Twisting Works
Static and Dynamic Control
Wind Tunnel Results: Efficiency and Comfort
Significant Noise Reduction
Vibration Dampening
International Collaboration
AirPro News Analysis
Frequently Asked Questions
The system reduces helicopter noise by up to 7 dB and vibrations by over 50 percent without using heavy mechanical parts.
It uses piezoceramic actuators embedded in the blade skin. These “artificial muscles” deform when voltage is applied, twisting the blade structure.
The project was led by DLR (Germany) with partners including NASA, the U.S. Army, ONERA, JAXA, KARI, Konkuk University, and DNW.
Sources
Photo Credit: DLR
MRO & Manufacturing
ExecuJet Haite Tianjin Facility Gains Bonded Maintenance Approval
ExecuJet Haite’s Tianjin facility secures bonded maintenance status, allowing duty-free spare parts import and reducing costs for international aircraft maintenance.
This article is based on an official press release from ExecuJet Haite.
ExecuJet Haite Aviation Services China Co., Ltd. has officially obtained bonded maintenance approval for its facility at Tianjin Binhai International Airport (ZBTJ). Announced on February 2, 2026, this regulatory milestone allows the maintenance, repair, and overhaul (MRO) provider to import aircraft spare parts and equipment duty-free when utilized within its designated bonded area.
According to the company’s press release, this approval is designed to significantly reduce operating costs and shorten turnaround times for international clients. By leveraging the new customs status, ExecuJet Haite aims to streamline the logistics of importing critical components, a move expected to bolster its competitiveness against regional hubs like Hong Kong and Singapore.
The core advantage of the bonded maintenance approval lies in the exemption from import duties for parts stored and used within the facility’s bonded zone. For business jet operators, particularly those with foreign-registered aircraft, this translates to a direct reduction in the tax burden associated with heavy maintenance visits.
In addition to cost savings, the facility anticipates a marked improvement in operational efficiency. The simplified customs procedures associated with the bonded status allow for faster access to spare parts, minimizing the downtime aircraft spend on the ground (AOG). Paul Desgrosseilliers, General Manager of ExecuJet Haite, emphasized the strategic importance of this development for the company’s diverse client base.
“This new status satisfies the demand of our international clients. While 60% of our work is for China-registered aircraft, 40% comes from a diverse international clientele. The bonded zone directly addresses their needs by significantly reducing costs and accelerating turnaround times.”
, Paul Desgrosseilliers, General Manager, ExecuJet Haite
ExecuJet Haite operates a 10,000-square-meter facility at Tianjin Binhai International Airport, featuring 2,640 square meters of dedicated hangar space. The company is a wholly-owned subsidiary of the Sichuan-based Haite Group but operates as a franchise of ExecuJet MRO Services, an entity owned by Dassault Aviation. This structure allows the facility to blend local market access with international service standards.
The facility holds Authorized Service Center (ASC) status for major OEMs including Gulfstream, Embraer, and Dassault Falcon Jet, and is certified to maintain Bombardier aircraft. Its regulatory approvals span the Civil Aviation Administration of China (CAAC), EASA, the FAA, and authorities in several offshore jurisdictions including the Cayman Islands and Bermuda. The approval of bonded maintenance status for ExecuJet Haite signals a maturing of the aviation services market in the Beijing-Tianjin-Hebei economic triangle. Historically, international operators have often favored hubs with free-port status, such as Hong Kong, to avoid the complex taxation and customs delays associated with mainland China. By removing the “tax penalty” for foreign jets through bonded maintenance, Tianjin effectively positions itself as a cost-effective alternative to Beijing Capital Airport.
This development aligns with broader trends within the Tianjin Pilot Free Trade Zone (FTZ), which has aggressively promoted aviation MRO services. The “bonded maintenance outside comprehensive bonded zones” pilot program allows standalone facilities,like ExecuJet Haite’s hangar,to enjoy the benefits of a free trade zone without being physically located inside one, provided they meet strict customs supervision standards.
We observe that this move is likely to intensify regional competition. While Lufthansa Technik maintains a strong presence in Tianjin focusing on commercial airline support, ExecuJet Haite is solidifying its dominance in the business aviation sector. With 40% of its workload already coming from foreign-registered aircraft, the ability to offer duty-free maintenance is a critical differentiator that could draw traffic away from saturated hubs in Southern China.
ExecuJet Haite Tianjin Secures Bonded Maintenance Status, Targeting International Fleet Efficiency
Operational Benefits for Cross-Border Aviation
Facility Capabilities and Reach
AirPro News Analysis: The “Beijing Alternative”
Policy-Driven Growth
Sources
Photo Credit: ExecuJet Haite
MRO & Manufacturing
RTX Invests $139 Million to Expand Aerospace Operations in Singapore
RTX plans over $139M investment in Singapore to boost aerospace manufacturing and MRO for Boeing 777X and 787 with AI integration by 2030.
This article is based on an official press release from RTX.
RTX, the world’s largest aerospace and defense company, has announced a significant expansion of its operational footprint in Singapore. In a statement released on February 3, 2026, during the Singapore Airshow, the company confirmed plans to invest more than $139 million (approximately S$185 million) into the region. The investment is structured through multiple Memoranda of Understanding (MOUs) signed with the Singapore Economic Development Board (EDB).
The new agreements specifically target RTX subsidiaries Collins Aerospace and Pratt & Whitney, aiming to bolster manufacturing and maintenance, repair, and overhaul (MRO) capabilities. According to the company’s announcement, these initiatives are designed to support next-generation Commercial-Aircraft, including the Boeing 777X and 787 Dreamliner, while integrating advanced Automation and AI into local workflows. The projected timeline indicates that these new capabilities will be fully operational by 2030.
This move reinforces Singapore’s status as a critical node in the global aerospace supply chain. RTX currently stands as the country’s largest foreign aerospace employer, with a workforce of over 4,300 spanning 12 facilities. The investment builds upon a strategic framework previously established between RTX and the EDB at the Paris Air Show in June 2025.
A major portion of the investment is allocated to Collins Aerospace, which will establish new MRO capabilities for critical systems on widebody aircraft. The press release details that the division will introduce support for the Integrated Drive Generators found on the Boeing 777X. Additionally, Collins Aerospace plans to expand its service offerings for the Boeing 787 fleet, specifically targeting “flight-critical” products.
These upgrades cover a range of essential aircraft components, including electrical power systems, environmental controls, and airframe control systems. By localizing these services, RTX aims to improve turnaround times and support the growing fleet of widebody aircraft operating within the Asia-Pacific region.
The investment also funds significant upgrades for Pratt & Whitney’s operations in Singapore, focusing on both capacity expansion and technological modernization. The company outlined specific plans for two of its key facilities:
At the Seletar facility, Pratt & Whitney will install a new maintenance line dedicated to the GTF™ engine Fan Drive Gear System (FDGS). This expansion is notable for its technological approach; the company states that the new line will leverage artificial intelligence (AI) and advanced automation. These tools are expected to streamline maintenance processes and reduce turnaround times for airline customers. Simultaneously, the Tuas facility will undergo a 25% expansion of its coating operations. This site specializes in applying protective coatings to engine “hot section” parts, a process vital for enhancing component durability and engine longevity.
Chris Haave, Vice President of International Operations at RTX, emphasized the long-standing relationship between the company and the host nation:
“These new MOUs build on our 50-year presence in the country and reflect our continued commitment to Singapore as a strategic hub for developing next-generation aerospace technologies. Together with EDB’s strong support, we are investing in capabilities that will support our customers in the region.”
The Singapore Economic Development Board (EDB) has actively courted investments that align with “Industry 4.0” standards, bringing smart manufacturing and high-value technical roles to the island state. While specific hiring numbers were not disclosed in the initial release, the EDB confirmed that the investment would generate high-value jobs focused on advanced manufacturing technologies.
Cindy Koh, Executive Vice President of the EDB, highlighted the dual benefits of the partnership:
“The expansion of new capabilities in next-generation commercial aircraft platforms will strengthen Singapore’s leadership as a global aerospace hub, and create exciting jobs for locals in advanced manufacturing technologies.”
The decision to integrate AI-driven maintenance lines at the Seletar facility signals a broader shift in the MRO sector toward predictive maintenance and automated quality control. As the Asia-Pacific region continues to project the highest growth rates for global passenger traffic, the demand for rapid, reliable MRO services is intensifying. By localizing the repair of complex components like the GTF Fan Drive Gear System and Boeing 777X generators, RTX is effectively shortening the supply chain for Asian carriers, reducing the reliance on shipping components back to facilities in the United States or Europe.
Sources:
RTX Commits $139 Million to Expand Singapore Aerospace Operations
Collins Aerospace: Focusing on Next-Gen MRO
Pratt & Whitney: AI Integration and Capacity Expansion
Seletar Facility Upgrades
Tuas Facility Expansion
Strategic Implications for the Region
AirPro News Analysis
Photo Credit: SHIKHAR GUPTA, BT
MRO & Manufacturing
Hadrian Opens $200M Factory 3 in Mesa Expanding Defense Manufacturing
Hadrian launches Factory 3 in Mesa, Arizona, investing $200M to create 350 jobs and enhance aerospace manufacturing with AI and automation.
This article is based on an official press release from Hadrian.
Hadrian, a company specializing in software-defined manufacturing, officially inaugurated its newest facility, Factory 3 (F3), in Mesa, Arizona, on January 29, 2026. According to the company’s press release, the event marks a significant milestone in Hadrian’s mission to modernize the American aerospace and defense supply chain through automation and artificial intelligence.
The new 290,000-square-foot facility represents a capital investment of $200 million in the region. Hadrian projects that the expansion will create approximately 350 high-skilled jobs, ranging from machinists to software engineers, by early 2026. The ribbon-cutting ceremony was attended by key stakeholders, including Arizona Governor Katie Hobbs, Mesa Mayor Mark Freeman, and Hadrian Founder and CEO Chris Power.
Hadrian distinguishes itself from traditional legacy manufacturers by utilizing a proprietary software operating system named “Opus.” This system manages the manufacturing lifecycle, from quoting to quality inspection, allowing the company to automate complex decision-making processes. In its announcement, the company stated that this technology enables the production of high-precision components for rockets, satellites, and jets up to 10 times faster than standard industry rates.
The Mesa facility is designed for “production autonomy,” aiming for machine uptime levels of 80-90%, a figure comparable to the automotive industry and significantly higher than the typical aerospace standard of approximately 30%. This efficiency is critical to Hadrian’s broader goal of “reindustrializing America” and addressing fragilities in the defense industrial base.
“Factory 3 is not just a facility, it’s a platform for AI-enhanced production that strengthens America’s industrial base… Our investment in Arizona was made possible through collaboration with state and local officials who share Hadrian’s commitment to make manufacturing meaningful work again.”
, Chris Power, Founder & CEO of Hadrian
The opening of F3 follows a period of rapid growth for the company. According to financial data and company reports referenced in the expansion announcement, Hadrian raised $260 million in Series C funding in July 2025 and holds a valuation of $1.6 billion. The Mesa factory will serve as a central hub for the company’s “Factory-as-a-Service” (FaaS) model.
Under this model, Hadrian dedicates specific production cells, comprising machines, robots, and software, to individual customers. This approach was highlighted by a strategic partnership announced in late 2025 with Lockheed Martin, which aims to embed Hadrian’s manufacturing capabilities directly into defense production lines for missile components. The launch of Factory 3 in Mesa underscores a critical shift in the aerospace supply chain: the move from artisanal, high-touch machining to scalable, software-driven production. For decades, the U.S. defense industrial base has struggled with long lead times and a shrinking workforce. Hadrian’s ability to secure high-profile contracts with prime contractors like Lockheed Martin suggests that the “Silicon Valley approach” to manufacturing, prioritizing iteration speed and software integration, is gaining serious traction among legacy defense giants. If the claimed 80-90% uptime is achieved at scale in Mesa, it could set a new benchmark for efficiency in a sector historically plagued by delays.
Mesa, Arizona, continues to solidify its reputation as a premier aerospace and defense hub. The region is already home to major operations for Boeing and other key suppliers. Governor Katie Hobbs emphasized the economic benefits of Hadrian’s arrival during the event.
“Hadrian’s investment in Mesa is a win for Arizona and America. By creating hundreds of family-sustaining jobs… this cutting-edge facility further positions Arizona at the forefront of America’s high-tech manufacturing resurgence.”
, Katie Hobbs, Governor of Arizona
To support the influx of high-tech manufacturing roles, Hadrian is leveraging Arizona’s workforce development ecosystem. The company noted active partnerships with Maricopa Community Colleges and Arizona State University (ASU) to train workers in advanced manufacturing and robotics, ensuring a steady talent pipeline for the new factory floor.
Hadrian Opens “Factory 3” in Mesa, Arizona, Marking $200 Million Expansion in Defense Manufacturing
Accelerating Production with “Software-Defined” Factories
Strategic Growth and “Factory-as-a-Service”
AirPro News Analysis
Regional Economic Impact
Frequently Asked Questions
Sources
Photo Credit: Hadrian
-
Business Aviation5 days agoBombardier Responds to U.S. Tariff and Certification Threats
-
Business Aviation6 days agoUS Threatens to Decertify Bombardier Jets in Canada Trade Dispute
-
Regulations & Safety6 days agoBritish Airways A350-1000 Lands Safely After Losing Wheel in Las Vegas
-
Regulations & Safety7 days agoChallenger 650 Crash in Maine Linked to De-Icing Limits and Wing Sensitivity
-
Business Aviation2 days agoDassault Announces Falcon 10X Rollout Date for March 2026