MRO & Manufacturing
Daher and Hexcel Fast Cure RTM Cuts Aerospace Lead Times
Daher and Hexcel demonstrate Fast Cure RTM process reducing aerospace composite part production lead times from 19 to 8 days with rapid-curing resins.
This article is based on an official press release from Daher.
The commercial aviation sector is currently facing a massive backlog of aircraft orders, placing unprecedented pressure on the supply chain to produce composite parts faster than ever before. On March 3, 2026, French aerospace manufacturers Daher announced a significant industrial breakthrough designed to address this exact bottleneck. Through a collaborative trial with advanced composites company Hexcel, Daher successfully demonstrated a “Fast Cure” Resin Transfer Molding (RTM) process that drastically accelerates production rates.
According to the official press release, this new methodology allows aerospace-grade composite parts to be manufactured at high speeds without the traditional requirement of multiplying expensive, large-scale manufacturing equipment. By shifting the focus from expanding physical infrastructure to accelerating the chemical curing process, the partnership has provided a viable pathway for scaling up production for next-generation Short and Medium Range (SMR) aircraft.
The results of the trial are striking. Daher reports that the Fast Cure process can reduce series production lead times for specific components from 19 days down to just eight days, fundamentally altering the industrial math for aerospace Original Equipment Manufacturers (OEMs).
The aerospace industry relies heavily on composite materials, such as carbon fiber, to reduce overall aircraft weight, improve fuel efficiency, and lower carbon emissions. However, traditional composite manufacturing processes are notoriously slow and resource-intensive. Standard Resin Transfer Molding (RTM), which involves injecting liquid resin into a closed mold containing a dry fiber preform and heating it to polymerize, provides excellent automation and complex geometric capabilities, but it struggles to meet modern volume demands.
Industry estimates indicate that some aircraft OEMs are targeting unprecedented production rates, occasionally aiming for up to 100 aircraft per month. Scaling up a standard RTM process to meet these high rates typically requires a brute-force industrial approach: investing in dozens of molds and multiple large heating ovens or massive autoclaves. This traditional method creates severe production bottlenecks and requires massive capital expenditure.
To break the cycle of simply buying more equipment to build more parts, Daher shifted its engineering focus to the manufacturing cycle itself. At the end of 2025, the company temporarily diverted production preforms and injection tooling from their standard serial production flow to test two specialized “Fast Cure” resins developed by Hexcel. According to the provided research data, Hexcel has spent recent years refining these rapid-cure, all-liquid format resins specifically to reduce takt time in high-rate aerospace manufacturing.
The trial utilized two specific Hexcel materials: The technological enabler of this successful trial was the implementation of isothermal injection. Daher’s engineers injected the resin at a constant temperature of 180 °C, followed immediately by a short curing phase and hot demolding. Hot demolding allows the composite part to be removed from the mold quickly, facilitating a rapid sequencing of operations that standard processes cannot match.
“By utilizing hot demolding and rapid curing, it becomes possible to process thermoset composites with the speed and agility typically reserved for thermoplastic materials.” Daher’s official release notes that the trial resulted in the successful manufacturing of six “production-type” parts, five utilizing the HF640 resin and one utilizing the HF610 resin. During the process, resin injection times were successfully kept below two minutes.
Crucially, speed did not compromise quality. The demonstrator parts were reintegrated into the plant’s standard downstream processes. Subsequent machining, ultrasonic non-destructive inspection, and geometric conformity checks revealed that the Fast Cure parts were entirely equivalent in quality to those manufactured using the slower, reference process.
The most compelling data points from the trial relate to industrial scalability. At very high production rates, Daher projects that a standard process would require over 30 molds and five ovens. By implementing the Fast Cure process, tooling requirements could be divided by eight, requiring only two molds and two mini-presses to achieve the same output.
Furthermore, the overall lead time for series production of these components could be slashed from 19 days at full rate under the standard process to just eight days using the Fast Cure methodology.
We view this development as a critical enabler for the broader aerospace supply chain. The global Resin Transfer Molding in Aerospace market was valued at approximately $1.73 billion in 2024 and is projected to grow at a Compound Annual Growth Rate (CAGR) of 9.2% through 2033, according to industry market-analysis. This growth is heavily dependent on the exact type of cost-efficient, high-performance manufacturing processes that Daher and Hexcel are pioneering.
Beyond raw speed, the Fast Cure process offers a vital strategic advantage: flexibility. Because the process relies on smaller, less permanent infrastructure, such as mini-presses rather than massive, fixed ovens, manufacturers gain the agility to reallocate equipment to different aircraft programs as market demands fluctuate. While the parts produced in this specific trial were non-airworthy demonstrators, this successful proof of concept lays the necessary groundwork for official certification and widespread industry adoption in the coming years.
RTM is a manufacturing process where liquid resin is injected into a closed mold containing dry fibers (like carbon fiber). The mold is then heated to cure the resin, creating a strong, lightweight composite part commonly used in aerospace.
According to Daher’s trial data, the Fast Cure process reduces the series production lead time for specific components from 19 days to 8 days, while utilizing resins that cure in as little as 15 to 30 minutes. Not yet. The parts produced in this trial were non-airworthy demonstrators used to prove the industrial viability of the process. This successful trial paves the way for future official qualification for flight.
Sources:
The Aerospace Production Bottleneck
The Demand for Composites
Scaling Challenges
Daher and Hexcel’s “Fast Cure” Innovation
Accelerating the Chemistry
The Isothermal Process
, Industry research summarizing the philosophical shift in Daher’s manufacturing approach.
Hard Data: Proving Industrial Scalability
Trial Results and Quality Assurance
Equipment and Lead Time Reductions
AirPro News analysis
Frequently Asked Questions (FAQ)
What is Resin Transfer Molding (RTM)?
How much faster is Daher’s Fast Cure process?
Are these Fast Cure parts currently flying on commercial aircraft?
Daher Official Press Release: Fast Cure & Furious
AirPro News Industry Research & Market Context Report
Photo Credit: Daher
MRO & Manufacturing
ÖAMTC and Airbus Sign Long-Term Contract for H135 H140 H145 Helicopters
ÖAMTC Flugrettung and Airbus Helicopters finalize a contract for H135, H140, and H145 helicopters, enhancing Austrian HEMS capabilities and cross-border cooperation.
This article is based on an official press release from Airbus Helicopters, supplemented by industry research reports.
At the Verticon 2026 trade show in Atlanta, Georgia, Austrian helicopter emergency medical services (HEMS) operator ÖAMTC Flugrettung and Airbus Helicopters finalized a strategic long-term framework contract. According to an official press release from Airbus, the agreement covers the acquisition of H135, H140, and H145 helicopters, securing ÖAMTC’s fleet modernization for the coming years.
This contract solidifies a letter of intent originally signed at last year’s Verticon in Dallas, officially cementing ÖAMTC as a launch customer and co-development partner for the new H140 light twin-engine helicopter. The Austrian operator currently relies heavily on Airbus rotorcraft, operating a fleet of 31 H135 helicopters across 18 permanent bases, one intensive care unit, and four winter bases.
We note that this agreement represents a significant milestone not only for Austrian air rescue but for the broader European HEMS market. It highlights an industry-wide shift toward highly capable, cost-efficient rotorcraft designed specifically to accommodate complex medical missions and heavier onboard equipment.
The H140, unveiled in March 2025, is Airbus’s first entirely new helicopter model developed in almost a decade. It is a 3-tonne class rotorcraft designed to bridge the capability and price gap between the entry-level H135 and the larger H145. Industry research details that the aircraft features a maximum takeoff weight (MTOW) of 3,175 kg (7,000 lbs) and is powered by twin Safran Arrius 2E turboshaft engines, each producing 700 shaft horsepower.
The Airbus press release highlights several key innovations, including a new T-shaped tail boom with an optimized Fenestron and a five-blade bearingless main rotor borrowed from the H145 to reduce vibration. Research reports indicate the T-tail design provides up to 80 kg (176 lbs) of additional lift in hover conditions. For medical crews, the cabin volume is approximately one cubic meter larger than the H135, featuring a completely flat floor and rear clamshell doors designed for the rapid loading of intensive care stretchers and transport incubators.
“This helicopter allows us to enter a new dimension of care. With its increased performance and space, this helicopter will be beneficial for those who use it every day. Our involvement in developing this new aircraft allowed us to create our own best-in-class medical interior,” said Marco Trefanitz, CEO of ÖAMTC Flugrettung, in the company’s release.
A unique aspect of the H140’s development is the unprecedented cross-border collaboration between operators. According to industry research, ÖAMTC Flugrettung and Germany’s ADAC Luftrettung, which has ordered 10 H140s, acted as joint development partners. Active flight rescue crews and technicians dictated the interior design, ensuring the aircraft meets real-world emergency medical needs.
This partnership extends beyond design. The two operators have harmonized their cockpit and cabin layouts, allowing for seamless interoperability. “For the first time, a helicopter generation will have a uniform configuration regarding cockpit and cabin layout across organizations, a milestone in our cooperation,” noted Trefanitz regarding the partnership with ADAC Luftrettung, according to industry reports.
We observe that the H140 hits a critical “sweet spot” in the current HEMS market. Operators are increasingly tasked with complex missions requiring heavier medical equipment and more personnel, which push the payload limits of smaller helicopters. However, upgrading entirely to the medium-twin H145 significantly increases acquisition and direct maintenance costs. By offering approximately 70 kg (154 lbs) more useful payload than the H135, the H140 provides the necessary space for advanced care while maintaining direct maintenance costs comparable to lighter models. Furthermore, the harmonized fleet agreement between ÖAMTC and ADAC Luftrettung creates a shared spare-parts and backup-helicopter pool. This strategic move will likely save operational costs and improve emergency response times across Central Europe, setting a new standard for cross-border HEMS cooperation.
The Airbus press release notes that the manufacturer is the leading provider of helicopters to the air medical transport industry, currently providing 54% of the 2,900 EMS helicopters flying worldwide. For ÖAMTC, which flew over 22,000 missions in 2025, averaging 61 missions per day, fleet reliability is paramount.
“For over 40 years, Airbus and ÖAMTC Flugrettung have shared a mission to save lives. We are deeply grateful for their continued trust in our helicopters and services. We look forward to seeing the H140 take flight in its iconic yellow livery, setting new standards for emergency care in Austria,” stated Bruno Even, CEO of Airbus Helicopters.
Industry reports highlight that this contract signature serves as a capstone achievement for Even. After an eight-year tenure that saw record profits, including 544 gross orders and 392 deliveries in 2025, Even is scheduled to step down on April 1, 2026. He will be succeeded by Matthieu Louvot, the current Executive VP of Strategy for the wider Airbus group.
According to Airbus, entry into service for the EMS segment is planned for 2028, following European Union Aviation Safety Agency (EASA) certification. Prototypes are currently undergoing flight testing out of Donauwörth, Germany.
The H140 is a larger, 3-tonne class helicopter that offers a cabin volume approximately one cubic meter larger than the H135. It features a five-blade main rotor, a new T-shaped tail boom for increased hover lift, and rear clamshell doors specifically designed for loading heavy medical equipment like transport incubators.
Sources:
The H140: A User-Designed Leap in HEMS
Co-Development and Medical Capabilities
Cross-Border Synergies and Fleet Economics
Harmonizing Operations
AirPro News analysis
Airbus Leadership and Market Position
End of an Era for Bruno Even
Frequently Asked Questions
When will the Airbus H140 enter service?
What makes the H140 different from the H135?
Airbus Helicopters Press Release
Industry Research Report: ÖAMTC Flugrettung and Airbus Helicopters Strategic Framework Contract (March 12, 2026)
Photo Credit: Airbus
MRO & Manufacturing
Patria and United Aero Group to Open European Helicopter Repair Center
Patria and United Aero Group partner to establish a European helicopter blade repair center, reducing maintenance times by 30% for rotorcraft operators.
This article is based on an official press release from Patria Group.
On March 10, 2026, Finnish defense and aviation company Patria and United States-based United Aero Group (UAG) signed a Memorandum of Understanding (MoU) at the VERTICON aviation trade show in Atlanta, Georgia. The agreement outlines a strategic initiative to establish a forward stocking location and a certified Helicopters blade repair center within Europe.
According to the official press release, this Partnerships is designed to localize the Supply-Chain for European rotorcraft operators. By bringing critical spare parts and specialized blade repairs directly to the continent, the initiative addresses long-standing industry bottlenecks. Project estimates cited in the announcement suggest the new facility will reduce MRO turnaround times by 30 percent compared to current industry norms.
For governmental and commercial operators, particularly those managing military defense, Emergency Medical Services (EMS), and Search and Rescue (SAR) fleets, this reduction in downtime is expected to significantly improve aircraft availability for high-stakes, mission-critical operations.
Historically, European helicopter operators have faced extended lead times for spare parts, often being forced to ship components to overseas facilities in North America for specialized repairs. This reliance on transatlantic shipping has traditionally led to logistical inefficiencies, elevated costs, and prolonged aircraft downtime.
The planned Patria-UAG facility aims to directly solve this logistical hurdle. By establishing a local hub, the partnership will provide European operators with immediate access to critical components and certified rotor blade repairs without the delays associated with intercontinental shipping.
Executives from both companies emphasized the operational and strategic benefits of the localized approach during the signing at the Georgia World Congress Center.
“Patria’s strong regional presence and operational capabilities combined with UAG’s global rotorcraft support expertise form a strong partnership. Together, Patria and UAG can minimize fleet downtime for European operators, accelerate access to mission-critical components, and offer certified blade repair services locally, strengthening the security of supply for helicopter fleets across Europe.”
— Pekka Ruutu, Executive Vice President of Sustainment Solutions at Patria
“Providing governmental and commercial rotorcraft operators with strong long-term solutions to keep their various fleets flying over Europe, operating at peak efficiency, with industry leading turn times, makes this a great partnership for the European market.”
— Thomas Neumann, CEO of United Aero Group
Patria Group brings over a century of experience in defense, security, and aviation life-cycle support. As a state-backed entity, owned 50.1 percent by the State of Finland and 49.9 percent by Norwegian defense group Kongsberg Defence & Aerospace AS, the company maintains a robust Northern European footprint with operations spanning Finland, Sweden, Norway, Belgium, the Netherlands, Germany, Latvia, and Japan.
United Aero Group is recognized globally for its parts, component sales, and support for helicopter models, historically focusing on Sikorsky (UH-60 Black Hawk, S-92) and Bell platforms. In 2022, UAG expanded its capabilities by acquiring Advanced Composite Structures (ACS), the world’s largest independent organization for helicopter rotor blade repair. This acquisition provided UAG with specialized expertise in composite and metal blade repairs for major Manufacturers, including Bell, Leonardo, Airbus, and Sikorsky.
This MoU represents a deepening of an existing strategic relationship. In October 2023, Patria and UAG entered into an initial cooperation agreement to jointly acquire pre-owned UH-60 Black Hawk helicopters from the U.S. Army, refurbish them with customer-specified mission kits, and market them to European nations.
We note that this commercial agreement aligns heavily with broader geopolitical trends, specifically the objectives of the European Defence Industrial Programme (EDIP). Following the outbreak of the war in Ukraine, European nations have aggressively pushed to secure their defense supply chains and reduce reliance on external logistics. Having a localized hub for military helicopter maintenance ensures that European defense forces can maintain high readiness levels without the risk of overseas supply chain disruptions.
Furthermore, the projected 30 percent reduction in maintenance turnaround time represents a massive operational boost for civilian sectors. Search and Rescue (SAR) and Emergency Medical Services (EMS) rely entirely on high fleet availability. A grounded helicopter waiting weeks for a rotor blade repair from the United States translates directly to a loss of emergency response capabilities in Europe. By localizing these repairs, Patria and UAG are directly contributing to the reliability of life-saving aviation infrastructure.
Sources: Patria Group
Localizing the European Rotorcraft Supply Chain
Leadership Perspectives
Strategic Background and Previous Collaborations
AirPro News analysis
Frequently Asked Questions (FAQ)
Photo Credit: Patria
MRO & Manufacturing
Aero Star Aviation Expands Maintenance Services to Cessna Citation Jets
Aero Star Aviation broadens MRO capabilities to service Textron Aviation’s Citation 560XL and Latitude jets, enhancing fleet support with AI and new facilities.
This article is based on an official press release from Aero Star Aviation. Supplementary industry context is drawn from third-party reporting.
On March 11, 2026, Dallas-based Aero Star Aviation announced a major strategic expansion of its maintenance, repair, and overhaul (MRO) capabilities. Historically recognized as a dedicated specialist in Embraer business jets, the company is officially opening its hangar doors to Textron Aviation’s Cessna Citation 560XL and Citation Latitude airframes.
According to the company’s press release, the new service offerings encompass scheduled and unscheduled maintenance, comprehensive inspections, troubleshooting, and dedicated airframe support. To facilitate this transition, Aero Star Aviation has invested heavily in specialized tooling and targeted maintenance technician training specific to the Citation models.
This expansion allows the MRO provider to tap into a massive existing fleet of popular midsize business jets. By broadening its scope, Aero Star aims to provide operators of Textron Aviation aircraft with the same streamlined service, reduced downtime, and technical excellence that its Embraer clients have historically received.
Aero Star’s decision to expand into these specific Textron Aviation models is highly strategic, driven by the massive market presence of both aircraft. The Cessna Citation 560XL family, which includes the Excel, XLS, and XLS+ variants, is one of the most successful midsize business jets in aviation history. With over 1,000 units delivered since its introduction in the late 1990s, the 560XL represents a vast, aging fleet that requires consistent, ongoing maintenance.
Similarly, the Cessna Citation Latitude, introduced in 2015, has been recognized as Textron Aviation’s best-selling midsize business jet for several consecutive years. The Latitude is highly popular among corporate flight departments and large fractional fleet operators, such as NetJets, ensuring a steady and lucrative pipeline of maintenance work for independent repair stations.
In the official press release, company leadership emphasized that their core values of safety and responsiveness will seamlessly transfer to the new airframes.
“Our reputation has been built on providing exceptional support for Embraer and Praetor aircraft. Adding the Citation airframe services allows us to extend that same commitment to safety, quality, and responsiveness to a wider segment of the business aviation community.” Founded in 2013, Aero Star Aviation operates out of its headquarters at Dallas Love Field (KDAL) in Texas, alongside a satellite facility in Fort Lauderdale, Florida. The company is an FAA-approved Part 145 repair station and holds Mexican AFAC certification, permitting it to service aircraft registered in Mexico. Prior to this announcement, the company built its reputation almost exclusively on servicing Embraer aircraft, specifically the Phenom 100 and 300 series, as well as the Praetor 500 and 600. To support its growing client base, the company has been on an aggressive physical growth trajectory. According to reporting by AviationPros in October 2024, Aero Star expanded into two larger hangars at Dallas Love Field, significantly increasing its footprint to 82,000 square feet of hangar space and 48,000 square feet of office space.
Beyond physical space, the MRO provider has also invested in cutting-edge technology to streamline its operations. As reported by Business Jet Interiors in late 2025, Aero Star introduced an AI-powered virtual assistant named “Ava.” This proprietary tool was designed to optimize troubleshooting and drastically reduce maintenance downtime for its technicians, a technological advantage that will now be applied to the Citation fleet.
The business aviation MRO sector is currently experiencing a surge in demand, often referred to by industry analysts as an “MRO supercycle.” Due to ongoing supply-chain constraints and backlogs in the production of new aircraft, operators are keeping older aircraft in service much longer than previously anticipated. This naturally increases the frequency, cost, and complexity of required maintenance.
Furthermore, airlines and private operators are increasingly outsourcing maintenance tasks to specialized, independent MROs. This shift allows operators to bypass severe bottlenecks at manufacturer-owned service centers, reduce aircraft downtime, and benefit from the cost efficiencies offered by independent shops.
We view Aero Star Aviation’s pivot as a textbook, highly calculated response to the current macroeconomic pressures in business aviation. By leveraging their recently expanded physical footprint at Dallas Love Field and their innovative AI troubleshooting tools, Aero Star is uniquely positioned to capture a significant share of the aging Citation fleet market. As factory service centers continue to face supply chain and scheduling delays, independent MROs that can guarantee reduced downtime and high-quality service will likely see outsized revenue growth over the next decade.
Sources:
Strategic Expansion into the Textron Market
Leadership Perspective
— Chris Grinnell, Owner and President of Aero Star Aviation
Aero Star’s Growth Trajectory and Technological Edge
AI Integration in Maintenance
Industry Context: The MRO Supercycle
AirPro News analysis
Frequently Asked Questions
As of March 2026, the company has expanded its services to include the Cessna Citation 560XL family (Excel, XLS, XLS+) and the Cessna Citation Latitude.
The company is headquartered at Dallas Love Field (KDAL) in Texas, with an additional satellite facility in Fort Lauderdale, Florida.
Supply chain constraints and new aircraft production backlogs are forcing operators to fly older aircraft for longer periods, which increases the need for frequent and complex maintenance.
Photo Credit: Aero Star Aviation
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