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 Production Bottleneck
The Demand for Composites
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.
Scaling Challenges
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.
Daher and Hexcel’s “Fast Cure” Innovation
Accelerating the Chemistry
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:
- HiFlow HF640F-2: A resin featuring a 15-minute polymerization (curing) time.
- HiFlow HF610F-2: A resin featuring a 30-minute polymerization time.
The Isothermal Process
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.”
, Industry research summarizing the philosophical shift in Daher’s manufacturing approach.
Hard Data: Proving Industrial Scalability
Trial Results and Quality Assurance
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.
Equipment and Lead Time Reductions
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.
AirPro News analysis
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.
Frequently Asked Questions (FAQ)
What is Resin Transfer Molding (RTM)?
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.
How much faster is Daher’s Fast Cure process?
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.
Are these Fast Cure parts currently flying on commercial aircraft?
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:
Daher Official Press Release: Fast Cure & Furious
AirPro News Industry Research & Market Context Report
Photo Credit: Daher
MRO & Manufacturing
BeauTech and Lufthansa GEM Sign 10-Year Engine Leasing Deal
BeauTech Power Systems and Lufthansa Group’s GEM sign a 10-year engine leasing framework covering CF34, CFM56, LEAP, and GTF platforms.
On June 22, 2026, Dallas-based BeauTech Power Systems, LLC and Group Engine Management GmbH (GEM), the dedicated engine management company of the Lufthansa Group, signed a 10-year engine leasing framework agreement. The decade-long contract secures long-term spare engine capacity for the European airline group across multiple engine platforms, reflecting a broader industry shift toward treating spare engines as structural necessities rather than short-term fixes.
In a press release announcing the deal, BeauTech stated the agreement covers a wide range of engine types, including the GE Aerospace CF34, CFM International CFM56 and LEAP, and the Pratt & Whitney Geared Turbofan (GTF). The partnership aims to support operational flexibility for Lufthansa Group airlines amid ongoing global supply chain constraints and extended maintenance turnaround times.
Securing capacity in a constrained market
Michael Kaye, Managing Director of GEM, emphasized the operational importance of the agreement for maintaining schedule reliability across the group’s fleets.
“Access to reliable engine capacity is an important component of supporting the operational requirements of the Lufthansa Group airlines. This agreement strengthens our ability to respond to changing fleet and maintenance needs while working with a trusted and experienced leasing partner,” Kaye said.
Tobias Konrad, Chief Operating Officer of BeauTech, noted that the Lufthansa Group has been a partner since BeauTech was founded in 2011. He stated the agreement underscores the trust built between the organizations over years of successful cooperation.
Strategic shift in spare engine planning
The extended duration of the framework agreement highlights a changing approach to engine management across the commercial aviation sector. According to reporting by Aviation Week, airlines are increasingly utilizing engine leasing to keep aircraft in service while their own powerplants undergo scheduled overhauls or unexpected repairs.
Speaking to Aviation Week, Konrad explained that BeauTech is positioned to support GEM whenever additional capacity is needed, including during Aircraft on Ground (AOG) situations or fast-turn lease requirements.
Konrad characterized the 10-year timeline as a sign of prudent planning by GEM, which already maintains a substantial internal spare engine pool. He noted that the decision to secure contracted external access over a decade reveals how top market players view spare-engine availability, describing it to the publication as “a structural feature of this decade, not a short-term squeeze.”
Konrad also told Aviation Week that leasing green time, which refers to the remaining operational life of an engine before its next scheduled overhaul, has evolved into a genuine fleet strategy rather than just a temporary fix for engine removals. Lessors have responded to this demand by developing more tailored leasing solutions.
AirPro News analysis
We view this 10-year framework agreement as a clear indicator that major airline groups do not expect engine supply-chain bottlenecks to resolve in the near term. By locking in a decade of access to spare engines across both legacy platforms like the CFM56 and CF34, as well as new-generation LEAP and GTF engines, the Lufthansa Group is hedging against prolonged maintenance delays.
The inclusion of new-generation engines is particularly notable. Both the LEAP and GTF programs have faced well-documented durability and supply chain challenges, increasing the global demand for spare units. This agreement positions BeauTech as a critical buffer for GEM, ensuring that Lufthansa Group airlines can maintain schedule reliability even as global MRO turnaround times remain elevated.
Sources: BeauTech Power Systems, LLC
Photo Credit: BeauTech Power Systems
MRO & Manufacturing
Safran Nacelles Delivers 5000th A320neo Nacelle
Safran Nacelles hits 5,000 A320neo nacelles with 100% on-time delivery and plans to scale output to 1,000 units per year.
Safran Nacelles has delivered its 5,000th nacelle for the Airbus A320neo program, maintaining a 100 percent on-time delivery rate as the manufacturer prepares to scale production to 1,000 units annually.
The milestone was celebrated on June 30, 2026, at Safran’s Colomiers facility near the Airbus final assembly line in Toulouse, France. According to a company press release, the achievement highlights the rapid production ramp-up required to support Airbus amid ongoing global Supply-Chain pressures.
Scaling production and supply chain performance
Safran Nacelles, working in conjunction with Middle River Aerostructure Systems, has insulated its A320neo nacelle output from broader industry bottlenecks. The company reported a flawless on-time Delivery record for the program to date, a metric it intends to protect as output increases.
What we are experiencing with the A320neo is unprecedented. This 5,000th Nacelle marks an important milestone and demonstrates the exceptional momentum of the programme. As demand continues to grow, we are preparing to produce up to 1,000 nacelles per year to support Airbus and Airlines around the world.
The statement from Safran Nacelles CEO Vincent Caro underscores the pressure on Tier 1 suppliers to match the pace of aircraft original equipment OEMs as they work through historic backlogs.
Airbus delivery targets and backlog pressure
The push for 1,000 nacelles per year aligns directly with Airbus’s aggressive production schedules. The European airframer is targeting 870 Commercial-Aircraft deliveries in 2026. Through the end of May 2026, Airbus had handed over 262 aircraft to 68 customers, including 81 deliveries in May alone.
The Airbus A320 family recently surpassed 20,000 total orders, cementing its status as a primary revenue driver for both Airbus and its supply chain partners. Fulfilling this backlog requires synchronized output across all major component providers, making nacelle availability a critical factor in final assembly.
AirPro News analysis
We view Safran’s 100 percent on-time delivery rate as a notable outlier in an aerospace supply chain otherwise defined by chronic delays and material shortages. Achieving a production rate of 1,000 nacelles annually will test the resilience of Safran’s sub-tier suppliers. If the company can maintain its delivery metrics at that volume, it will remove a critical potential chokepoint for Airbus as the airframer chases its 870-aircraft target for 2026.
Sources: Safran Group
Photo Credit: Safran Group
MRO & Manufacturing
FTG Opens First India Facility in Hyderabad Aerospace Park
Firan Technology Group opened its Hyderabad facility on June 29, 2026, producing avionics and cockpit electronics for global OEMs.
Firan Technology Group Corporation (FTG) officially opened its first Indian manufacturing facility on June 29, 2026, establishing a new production hub for cockpit and avionics components within the GMR Aerospace and Industrial Park in Hyderabad.
Announced via a company press release, the FTG Aerospace Hyderabad facility culminates a three-year strategic effort to expand the Canadian manufacturer’s global footprint. The new site provides low-cost capacity to support Western demand for commercial and defense aerospace products while mitigating risks associated with restrictive trade policies in other global markets.
Strategic expansion and local integration
The customized Built-to-Suit unit was developed by GMR Hyderabad Aviation SEZ Limited (GHASL). It is situated within a 277-acre aerospace and industrial park, integrating FTG into an established airport-led ecosystem. The facility will focus on designing and manufacturing high-reliability printed circuit boards (PCBs), illuminated cockpit products, electronic assemblies, and cockpit interface electronics for global original equipment manufacturers (OEMs).
In the press release, FTG President and CEO Brad Bourne described the opening as a strategic milestone for the company.
“GMR’s world-class Built-to-Suit infrastructure and integrated, airport-led ecosystem give us an ideal platform to deliver the high-reliability avionics and cockpit interface electronics our global OEM customers depend on,” Bourne stated.
Bourne also noted that significant work remains to fully operationalize the site. The company is currently focused on adding and training staff, securing necessary industry certifications, obtaining customer approvals, and ramping up production.
Aligning with domestic manufacturing initiatives
The Hyderabad operation brings FTG’s manufacturing presence to four countries, joining existing facilities in Canada, the United States, and China. The expansion aligns directly with the Indian government’s “Make in India” policy, positioning the company to serve both domestic defense requirements and international export markets.
Aman Kapoor, CEO of GMR Airport Land Development, stated that the launch marks a significant step in building a globally competitive aerospace manufacturing ecosystem in the region. Kapoor emphasized that FTG’s presence will strengthen domestic supply chains and advance indigenization efforts, further cementing Hyderabad as a primary hub for aerospace and industrial innovation.
AirPro News analysis
We view FTG’s expansion into India as a calculated hedge against ongoing geopolitical and trade friction. By establishing a secondary low-cost manufacturing base outside of China, FTG provides its Western aerospace and defense customers with a more resilient supply chain. The choice of Hyderabad specifically leverages an existing aerospace cluster, which should help accelerate the complex certification and approval processes required for aviation electronics production.
Sources: Firan Technology Group Corporation
Photo Credit: The Hindu
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