MRO & Manufacturing
Daher Industrializes Thermoplastic Composite Upcycling in Aerospace
Daher accelerates industrial-scale upcycling of thermoplastic composites, recycling aerospace scrap into high-performance materials for aircraft manufacturing.
This article is based on an official press release from Daher.
French aerospace manufacturers Daher has announced a significant acceleration in the industrialization of thermoplastic composite upcycling. According to an official company press release, the group is preparing to supply upcycled materials to manufacturers facing challenges with production ramp-ups, material sovereignty, and decarbonization.
The announcement, made during the JEC World 2026 trade show in Paris, highlights Daher’s transition from research and development to industrial-scale deployment. The company confirmed it is structuring a complete upcycling value chain, capturing scrap material and reintroducing it into new manufacturing cycles.
As part of this initiative, Daher received two JEC Innovation Awards, recognizing its advancements in both aeronautical parts manufacturing and end-of-life aircraft recycling. The company noted that it has spent more than 10 years investing in thermoplastic composites to meet the rigorous demands of modern aeronautical programs.
Transforming Factory Scrap into Technical Materials
The foundation of Daher’s upcycling strategy begins on the factory floor. In its press release, the company detailed a structured process implemented at its Saint-Aignan-de-Grandlieu plant in France’s Loire-Atlantique region, working in tandem with its Shap’in technology center. Production scrap is collected on-site, ground down, and transformed into a semi-finished product.
Currently, Daher reports that 100 percent of its pure carbon polyphenylene sulfide (PPS) scrap is upcycled through this method. The end result is a specialized pellet containing 56 percent carbon fiber. Because the material is derived from continuous fibers that are reprocessed into short fibers, it maintains high mechanical performance, including strong resistance to temperature, moisture, and chemical exposure.
Scaling Up Production Capacity
The industrial scale-up of this process is expected to yield an estimated production capacity of four to eight metric tons of carbon PPS pellets per year. Daher noted in the release that it currently has 1.5 metric tons available for sale and is actively exploring customer applications, including uses outside the traditional aeronautics sector.
Additionally, the company has utilized the same scrap material to develop a filament for additive manufacturing, creating new avenues for 3D printing complex technical parts. A component produced using this new filament was displayed at the company’s JEC World 2026 booth.
Repurposing End-of-Life Aeronautical Structures
Beyond factory scrap, Daher is applying its thermoplastic expertise to retired aircraft components. A notable project, which secured a 2026 JEC Innovation Award, involves a collaboration with Airbus, Toray Advanced Composites, and Tarmac Aerosave.
According to the company statement, this partnership successfully recycled thermoplastic composite panels from a retired A380 aircraft. The panels were cut and reintegrated into the production line to manufacture new parts for the A320neo program. This demonstration underscores the viability of circular manufacturing in commercial-aircraft.
“For more than 10 years, we’ve invested in thermoplastic composites to meet aircraft manufacturers’ requirements in terms of production rates, weight reduction and performance. Today, we are taking a further step by industrializing materials derived from upcycling. This capability allows us to optimize the use of a strategic material, strengthen our material autonomy and open new application opportunities, both in aeronautics and beyond.”
AirPro News analysis
We view Daher’s announcement as a critical indicator of the aerospace industry’s broader shift toward circular economy principles. As supply-chain constraints and material sovereignty remain pressing issues for global manufacturers, the ability to reclaim and reuse high-performance materials like carbon PPS offers a strategic buffer.
Furthermore, the successful integration of upcycled A380 panels into the A320neo production line demonstrates that recycled composites can meet the rigorous safety and performance standards required for commercial flight. If scaled effectively, these upcycling processes could significantly reduce the carbon footprint of aircraft manufacturing while lowering raw material costs.
Frequently Asked Questions
What is thermoplastic composite upcycling?
It is the process of taking scrap or end-of-life thermoplastic composite materials and reprocessing them into new, high-performance materials for manufacturing, rather than discarding them as waste.
How much upcycled material can Daher produce?
According to the company, the scaled-up process has an estimated production capacity of four to eight metric tons of carbon PPS pellets per year, with 1.5 metric tons currently available for sale.
What aircraft are involved in Daher’s recycling project?
Daher partnered with Airbus, Toray Advanced Composites, and Tarmac Aerosave to recycle thermoplastic panels from a retired A380 and use them to produce new parts for the A320neo.
Sources
Photo Credit: Daher
MRO & Manufacturing
Ornge Goes Paperless with Ramco Digital Maintenance Platform
Ontario air ambulance provider Ornge completes paperless maintenance transition using Ramco Systems, meeting Transport Canada compliance requirements.
Ontario-based air ambulance provider Ornge has transitioned its maintenance operations to a fully paperless workflow across all bases following the implementation of Ramco Systems’ digital maintenance platforms.
Announced in an August 25, 2026, press release, the transition utilizes Ramco’s Digital Task Card with eSign-off and the Mechanic Anywhere Mobile Application. The system supports Ornge’s fleet of Leonardo AW-139 helicopters and Pilatus PC-12 fixed-wing Commercial-Aircraft, meeting Transport Canada (TC) compliance requirements for digital maintenance sign-offs.
Modernizing maintenance execution
The shift replaces traditional paper-based task cards with a mobile-enabled system, allowing Aircraft Maintenance Engineers (AMEs) to execute and sign off on tasks in real time. The integration is designed to streamline turnaround times for the critical air ambulance fleet.
“In addition to helping us go paperless, Ramco’s Digital Task Card and Mechanic Anywhere app is well positioned to help us in our efforts to ensure timely maintenance turnaround times,” said Robert Zwanenburg, Technical Services Manager at Ornge.
Zwanenburg noted the importance of providing front-line crews with accessible tools regardless of their working location, ensuring that maintenance personnel can update records directly from the hangar floor or flight line.
Broader industry shift toward digital MRO
The Ornge implementation aligns with a wider aviation industry trend of adopting digital Maintenance, Repair, and Overhaul (MRO) platforms. Manoj Kumar Singh, Chief Customer Officer for Aviation, Aerospace & Defense at Ramco Systems, stated that aviation maintenance is moving toward a mobile-first future, citing the Ornge deployment as a practical example of this shift.
Ramco Systems has recently expanded its footprint in the aviation software sector. On August 24, 2026, the company announced a contract with Royal Jordanian Airlines to modernize its fleet maintenance and engineering operations. Earlier in the month, on August 20, 2026, FAA- and EASA-certified engine MRO provider Pem-Air also selected Ramco Aviation Software to manage its maintenance operations and transition toward paperless workflows.
AirPro News analysis
We view the digitization of maintenance records as a critical operational upgrade for specialized operators like Ornge. Air ambulance services require high dispatch reliability, and reducing the administrative friction of paper-based compliance can directly impact aircraft availability. Transport Canada’s acceptance of digital sign-offs enables operators to maintain strict regulatory Compliance while accelerating the return-to-service process for both rotary and fixed-wing assets.
Sources: Ramco Systems
Photo Credit: Ramco Systems
MRO & Manufacturing
Textron Aviation Earns CASA Part 145 Approval in Australia
Textron Aviation secures CASA Part 145 certification for three Australian service centers supporting 1,400+ aircraft.
Textron Aviation has secured Part 145 approval from Australia’s Civil Aviation Safety Authority (CASA), authorizing the manufacturer to provide factory-direct maintenance and overhaul services across its three company-owned Australian facilities.
Announced in a press release on August 26, 2026, the certification establishes one of the most comprehensive original equipment manufacturer (OEM) support networks in the country. The approval covers Textron Aviation service centers in Melbourne, Perth, and the Gold Coast, enabling the company to support a regional fleet of more than 1,400 Cessna, Beechcraft, and Hawker aircraft.
Expanding the Asia-Pacific footprint
The CASA Part 145 certification represents the culmination of a multi-year expansion strategy in the Asia-Pacific market. On January 6, 2020, Textron Aviation acquired Australian maintenance, repair, and overhaul (MRO) provider Premiair Aviation Maintenance.
The manufacturer officially rebranded the acquired facilities to Textron Aviation Australia on June 12, 2024, integrating them into a global network that includes more than 300 authorized service facilities and over 40 mobile service units.
Earlier this year, on May 5, 2026, the company opened a purpose-built, 35,000-square-foot service center at Essendon Fields Airport in Melbourne. This new facility more than doubled the company’s previous maintenance capacity in the city, setting the stage for the regulatory approval required to operate as a fully certified OEM maintenance organization.
Factory-direct service capabilities
With the regulatory approval now in place, Textron Aviation can perform a wider range of services directly rather than relying on third-party MRO providers. The CASA Part 145 certificate verifies that the company’s maintenance organization meets Australia’s stringent aviation safety and quality standards.
The authorization permits the facilities to conduct routine maintenance, complex modifications, and full overhauls. It also enhances the company’s ability to dispatch aircraft-on-ground (AOG) support for operators experiencing unscheduled maintenance events across the continent.
AirPro News analysis
We view this regulatory milestone as a critical step in Textron Aviation’s strategy to capture more aftermarket revenue while tightening its relationship with Asia-Pacific operators. By bringing former third-party MRO operations fully under the corporate umbrella and securing the necessary CASA approvals, the manufacturer ensures that Australian owners of Cessna, Beechcraft, and Hawker aircraft remain within the factory service ecosystem. This localized, factory-direct model reduces downtime for operators and provides Textron Aviation with a stable, long-term revenue stream in a geographically isolated but highly active business aviation market.
Sources: Textron Aviation
Photo Credit: Textron Aviation
MRO & Manufacturing
Electra Invests $850M in Ohio Plant for EL9 Aircraft
Electra commits $850M to build an EL9 hybrid-electric aircraft facility in Springfield, Ohio, targeting 400 aircraft per year.
Electra has committed $850 million to build its first scaled manufacturing facility in Springfield, Ohio, where the company will produce its EL9 Ultra Short hybrid-electric aircraft. The investment is projected to generate 1,975 jobs in Clark County and marks the transition of the nine-passenger aircraft from development to commercial production.
Announced on July 21, 2026, at the Farnborough International Airshow, the agreement with JobsOhio and state officials places the new plant at AirPark Ohio, adjacent to the Springfield-Beckley Municipal Airport. The EL9, which traces its origins to a Massachusetts Institute of Technology (MIT) class project, utilizes blown-lift technology to operate from unconventional spaces.
Production capacity and regional impact
The Springfield facility will initially support a production rate of 400 aircraft per year. Electra plans to eventually double this capacity to 800 airframes annually as the program matures and market demand dictates.
Ohio Governor Mike DeWine highlighted the state’s historical ties to aviation and its current focus on advanced air mobility (AAM) manufacturing.
“Ohio is where flight began, and the Dayton-Springfield area has become the national epicenter for advanced air mobility,” DeWine stated in a press release. “Electra’s decision to bring nearly 2,000 new jobs to Springfield will be transformative for Clark County.”
Electra CEO Marc Allen emphasized the importance of the Ohio site selection for the program’s next phase, noting the region’s established aerospace and defense ecosystem.
“This agreement is the moment that our vision moves from demonstration into reality,” Allen said. “In Springfield and Clark County, we found the rare combination this next era requires: a ready site, a skilled workforce, a deep aerospace and defense ecosystem, and state and local leaders with the commitment and vision to build it with us.”
Aircraft capabilities and recent milestones
The EL9 Ultra Short is designed to carry nine passengers and requires a minimum runway length of just 150 feet for takeoff and landing. Electra refers to this operational model as “Direct Aviation,” targeting point-to-point transport using infrastructure such as parking lots, barges, and sports fields rather than traditional airport runways.
The aircraft’s development has accelerated in recent weeks. On July 10, 2026, Electra reached an initial certification milestone with the Federal Aviation Administration (FAA). Five days later, the manufacturer finalized an agreement with Safran to develop and produce the TG600 Turbogenerator, which will power the EL9.
An August 25, 2026, feature published by MIT News detailed the aircraft’s academic roots, noting its evolution from a classroom concept to a fully funded commercial program.
AirPro News analysis
We view Electra’s $850 million manufacturing commitment as a critical indicator of maturity in the hybrid-electric aviation sector. While much of the advanced air mobility industry has focused on electric vertical takeoff and landing (eVTOL) designs, Electra’s blown-lift, fixed-wing approach offers a distinct payload and range profile while still minimizing infrastructure requirements. Securing a dedicated production facility with substantial state backing suggests the company is successfully navigating the transition from prototyping to industrialization, a phase that has historically challenged new aerospace entrants.
Sources: MIT News, Electra Newsroom
Photo Credit: Electra
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