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
Embraer Acquires Full Ownership of EZ Air Interior
Embraer buys remaining 50% of EZ Air from Safran Cabin to secure E-Jet cabin supply ahead of a major production ramp-up.

Embraer has taken full ownership of its interior components supplier, EZ Air Interior Limited, acquiring the remaining 50 percent stake from Safran Cabin on July 1, 2026, to secure its supply chain amid a major production ramp-up.
The transaction, announced in a company press release, gives the Brazilian aerospace manufacturers complete control over the production of critical cabin elements for its E-Jets family. The agreement also includes the integration of specific Safran Cabin operations located in JacareÃ, Brazil, into Embraer’s manufacturing footprint.
Consolidating the cabin supply chain
Established in 2012 in Chihuahua, Mexico, EZ Air was originally formed as a joint venture between Embraer and C&D, a company that was later absorbed into Safran Cabin. The Chihuahua facility specializes in manufacturing essential interior components, including luggage bins, galleys, lavatories, and floor panels for commercial-aircraft.
Embraer President and Chief Executive Officer Francisco Gomes Neto stated the acquisition aligns with the company’s strategy to expand operations in both the short and long term, while continuously evaluating opportunities to create value for stakeholders.
“I would like to thank Safran Cabin for this successful long-term partnership and warmly welcome the new colleagues joining Embraer. Together, we will continue to deliver excellence driven by safety, quality, efficiency and sustainability,” Gomes Neto said.
Production targets and backlog pressures
Embraer is actively working to stabilize its supply-chain to meet a record firm order backlog, which reached $32.1 billion in the first quarter of 2026. The manufacturer is targeting an annual production rate of approximately 100 E-Jet aircraft by 2027 or 2028.
Securing full ownership of EZ Air mitigates execution risks as Embraer increases the output of its E175 and E2 family aircraft. By bringing the production of critical interior components entirely in-house, the company aims to insulate its final assembly lines from external supplier delays.
AirPro News analysis
We view this acquisition as a defensive vertical integration move typical of the current aerospace manufacturing environment. With global supply chains remaining fragile, original equipment manufacturers (OEMs) are increasingly bringing critical component production in-house to prevent bottlenecks. By taking full control of EZ Air, Embraer eliminates a potential single point of failure in its E-Jet assembly line, ensuring that cabin interior shortages do not derail its ambitious delivery targets over the next two years.
Sources: Embraer
Photo Credit: Embraer
MRO & Manufacturing
Lufthansa Technik Breaks Ground on Portugal MRO Facility
Lufthansa Technik starts construction on a 55,000 sq-meter MRO facility in Portugal, creating up to 700 jobs by 2028.

Lufthansa Technik broke ground on a new 55,000-square-meter MRO facility in Santa Maria da Feira, Portugal, on June 29, 2026. The project is expected to create up to 700 highly skilled jobs when operations begin in 2028.
Announced via a company press release, the “three-digit million-euro” investment will focus on the repair of engine parts and aircraft components. The ceremony drew high-level political and corporate attendance, with Lufthansa Group leadership explicitly linking the industrial commitment to their strategic interest in acquiring a stake in the national carrier, TAP Air Portugal.
Transitioning to a permanent MRO footprint
Lufthansa Technik Portugal was founded in 2024 and has been operating out of a temporary three-building site at the PERM business park in Santa Maria da Feira. According to reporting by Aviation Week, this interim facility achieved European Union Aviation Safety Agency (EASA) Part 145 maintenance certification earlier in 2026, enabling the transition from training to certified maintenance work.
The new permanent facility represents a major expansion of these capabilities. The Portuguese investment agency, Agência para o Investimento e Comércio Externo de Portugal (AICEP), is providing €24.75 million in economic development funds for the project, drawn from a pool of €223 million in eligible funding.
“By creating 700 highly qualified jobs and bringing cutting-edge capabilities to Portugal, this investment will reinforce the country’s position as a leading aviation and MRO hub in Europe,” said Madalena Oliveira e Silva, Chairwoman and CEO of AICEP.
The TAP Air Portugal acquisition strategy
The groundbreaking occurs as the Portuguese government revives the privatization process for TAP Air Portugal. Lufthansa Group is actively competing to acquire a minority stake in the flag carrier.
During the June 29 ceremony, Lufthansa Group CEO Carsten Spohr directly connected the MRO investment to the acquisition bid.
“This depth of commitment across industry and innovation also underpins our strong interest in TAP Air Portugal as a natural extension of the partnership with Portugal we have been building for decades,” Spohr stated, noting the country serves as Europe’s gateway to South America and Africa.
The MRO facility is part of a broader expansion by the Lufthansa Group in the country, which includes a new TravelTech and AI Hub in Northern Portugal. The company aims to create more than 1,000 direct jobs across its Portuguese businesses in the coming years to support its 353 weekly flights to Portuguese destinations.
AirPro News analysis
We view the scale and timing of the Santa Maria da Feira facility as a calculated demonstration of industrial value by the Lufthansa Group, aimed directly at Portuguese policymakers. By committing a nine-figure sum and establishing a permanent EASA Part 145 certified footprint before the TAP Air Portugal privatization concludes, Lufthansa is positioning itself not just as a financial bidder, but as an integrated aerospace partner for the Portuguese economy. The presence of Prime Minister LuÃs Montenegro at the groundbreaking underscores that this message is being received at the highest levels of government.
Sources: Lufthansa Technik
Photo Credit: Lufthansa Technik
MRO & Manufacturing
Velo3D Triples Capacity With New Livermore Manufacturing Facility
Velo3D opens a 288,747-sq-ft Livermore campus to expand metal additive manufacturing for aerospace and defense.

Metal additive manufacturing provider Velo3D is tripling its production capacity with a new 288,747-square-foot facility in Livermore, California, aiming to support the aerospace and defense sectors as they transition from prototyping to full-scale 3D-printed component production.
In a press release issued on June 30, 2026, the company detailed plans to bring the new production campus online later this year. The expansion creates one of the largest metal additive manufacturing footprints in North America, while Velo3D retains its existing Fremont, California, headquarters as a dedicated research and development hub.
Facility specifications and production scale
The Livermore site dedicates 270,000 square feet specifically to manufacturing operations. The building features 36-foot clear heights, providing nearly 10 million cubic feet of vertical volume required to house the company’s large-format additive manufacturing systems.
At launch, the facility is designed to support more than 40 large-format systems. The site infrastructure allows for future expansion to accommodate over 100 metal 3D printers. Combined with the Fremont location, Velo3D will have the capacity to support a total of 125 machines.
“We believe additive manufacturing should be accessible, scalable, and production-ready,” said Michelle Sidwell, Chief Revenue Officer at Velo3D.
Aerospace and defense market momentum
The physical expansion follows a period of revenue growth driven by defense and aerospace contractors adopting the company’s Rapid Production Solutions (RPS) and Sapphire metal 3D printers. In May 2026, Velo3D reported first-quarter revenue of $13.8 million, representing a 48 percent year-over-year increase.
Earlier in 2026, the company secured an $11.5 million multi-year production agreement with a major U.S. defense contractor. This followed a February 10, 2026, announcement that Velo3D was selected as the first qualified additive manufacturing provider for the U.S. Army Ground Vehicle Systems Center.
Financial analysts have noted the company’s alignment with domestic manufacturing initiatives. On June 25, 2026, Needham analyst Austin Bohlig initiated coverage of Velo3D with a Buy rating and a $33 price target, forecasting $65 million in revenue for 2026.
“We believe the company’s leading metal additive manufacturing platform is becoming a critical enabling technology for the reindustrialization of the U.S. aerospace and defense (A&D) industrial base,” Bohlig stated.
Market positioning and conflicting outlooks
On June 29, 2026, Velo3D was officially added to the Russell 3000 Index and the Russell Microcap Index. Chief Executive Officer Arun Jeldi indicated the inclusion is intended to broaden the company’s visibility among institutional investments.
AirPro News analysis
We observe a sharp divergence in market sentiment surrounding Velo3D’s growth trajectory. While the company is executing tangible physical expansions and securing multi-million dollar defense contracts, it faces aggressive skepticism from some market participants. The simultaneous June 25, 2026, release of Needham’s bullish forecast and a bearish short-seller report from Morpheus Research highlights this tension. Morpheus characterized the business as a “promotional grift,” contrasting starkly with the company’s reported 17.2 percent gross margin improvements and transition to full-scale production. The successful activation and utilization of the Livermore facility later in 2026 will likely serve as the primary indicator of whether the aerospace supply chain can sustain this expanded capacity.
Sources: Velo3D, Inc. / PR Newswire
Photo Credit: Velo3D
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