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
IAI Advances Airbus A330-300 Passenger-to-Freighter Conversion
Israel Aerospace Industries completes key structural modifications on Airbus A330-300 P2F, entering flight testing with certification expected by year-end.
Israel Aerospace Industries (IAI) has announced a significant advancement in its Airbus A330-300 passenger-to-freighter (P2F) conversion program. According to an official press release, the first aircraft undergoing this transformation has officially come off the jacks, signaling the completion of its primary structural modifications.
This milestone moves the widebody conversion program into its critical ground and flight testing phase. IAI stated that the inaugural flight of the newly converted freighter is slated to occur in the coming weeks, with full certification anticipated by the end of the year.
The development underscores IAI’s expanding footprint in the global air cargo market, adding the A330-300 to a portfolio that already includes complex conversions for both Boeing and Airbus platforms.
Expanding Cargo Capacity and Market Reach
The A330-300BDSF conversion is engineered to meet the growing global demand for dedicated Cargo-Aircraft. According to the company’s press release, the modified aircraft will offer a payload capacity of up to 61 tons and accommodate up to 30 cargo containers.
Designed primarily for regional and medium-haul operations, the freighter features an advanced cargo handling system and optimized cargo flow. IAI noted that the forward positioning of the main deck cargo door is specifically intended to reduce turnaround times by facilitating faster loading and unloading procedures.
Leadership Perspectives
Company executives emphasized the strategic importance of the A330-300 program in addressing the evolving needs of Airlines, leasing companies, and cargo operators.
“This achievement marks another step in executing IAI’s long-term vision to expand its role in the global air cargo market. By continuously advancing our technological and industrial capabilities, we are positioned to deliver scalable and reliable solutions that align with our customers’ evolving operational needs, while reinforcing our leadership in the conversion arena.”
, Boaz Levy, President and CEO of IAI
A Legacy of Freighter Conversions
With over 45 years of experience in the aviation sector, IAI has established itself as a premier conversion house. The company highlighted in its release that it is trusted by major industry players, including Amazon, DHL, and Gulfstream Aerospace.
The A330-300 program joins an extensive lineup of successful P2F conversions. IAI was notably the first company globally to secure a Supplemental Type Certificate (STC) for the Boeing 777-300ER passenger-to-freighter conversion.
Broad Product Portfolio
Beyond the new Airbus initiative and the 777-300ER, IAI’s current conversion portfolio encompasses a wide range of aircraft. The company performs advanced modifications on widebody Boeing 767-200 and 767-300 models, as well as narrowbody Boeing 737-700 and 737-800 aircraft.
“Our A330-300 passenger-to-freighter conversion has been purpose-built to meet evolving market demand, delivering a highly competitive value proposition and strong market appeal. As one of the few companies worldwide with the capability to execute comprehensive and highly complex conversions across both narrowbody and widebody aircraft, IAI offers customers greater fleet flexibility…”
, Yaacov Berkovitz, EVP & GM, IAI’s Aviation Group
AirPro News analysis
At AirPro News, we note that the successful structural completion of the A330-300 P2F conversion highlights a broader industry trend: the continued reliance on converted passenger jets to feed the global e-commerce and logistics supply chain. As older passenger fleets are retired, converting these airframes provides a cost-effective alternative to purchasing purpose-built freighters. We believe IAI’s ability to offer conversions across both major Manufacturers, Airbus and Boeing, positions the company uniquely to capture market share regardless of which aircraft type an operator prefers.
Frequently Asked Questions
What is a passenger-to-freighter (P2F) conversion?
A P2F conversion involves heavily modifying a retired or older passenger aircraft to carry cargo. This typically includes reinforcing the floor, installing a large main-deck cargo door, and adding specialized cargo handling systems.
When will the IAI A330-300 freighter be certified?
According to the company’s press release, IAI expects the converted A330-300 to receive Certification by the end of the year, following ground and flight tests.
How much cargo can the converted A330-300 carry?
The A330-300BDSF conversion offers a payload capacity of up to 61 tons and can hold up to 30 containers.
Sources
Photo Credit: Israel Aerospace Industries
MRO & Manufacturing
H.B. Fuller Launches Aerospace Center of Excellence in Charlotte
H.B. Fuller will open a new Aerospace Manufacturing Center of Excellence in Charlotte, NC, in 2027 to support aviation, space, and defense markets.
This article is based on an official press release from H.B. Fuller Company.
H.B. Fuller Company, the world’s largest pureplay adhesives provider, has announced plans to establish a new Manufacturing Center of Excellence in Charlotte, North Carolina. Expected to open in early 2027, the purpose-built facility is designed to accelerate the company’s growth across the aviation, space, and defense markets.
The investment represents a critical step in “Project Quantum Leap,” an enterprise-wide initiative launched by H.B. Fuller to optimize its global manufacturing footprint. According to the company’s press release, the project aims to concentrate resources on the highest-value and highest-margin segments of its extensive portfolio.
As the aerospace industry increasingly relies on advanced adhesives to replace traditional mechanical fasteners, the new Charlotte facility will position H.B. Fuller to meet stringent regulatory standards while expanding its capacity to support long-term program continuity for its global customer base.
Consolidating Aerospace Operations in North Carolina
Facility Capabilities and Certifications
The upcoming Aerospace Manufacturing Center of Excellence will consolidate specialized manufacturing, packaging, testing, and quality operations into a single, tightly controlled environment. According to the company, the site is engineered specifically to meet the rigorous demands of aerospace manufacturing, featuring purpose-designed production systems, specialized mixing equipment, and dedicated laboratories for product development and validation.
To ensure compliance with the aviation and defense sectors’ strict quality requirements, H.B. Fuller expects the facility to achieve AS9100 certification, the benchmark quality management standard for the industry. Furthermore, the company plans to pursue Nadcap accreditation, widely recognized as the gold standard for special process quality assurance in aerospace.
“This Manufacturing Center of Excellence brings together advanced infrastructure, deep technical expertise, and rigorous quality systems in one purpose-built operation,” stated João Magalhães, senior vice president of Engineering Adhesives at H.B. Fuller, in the official release.
Magalhães added that the facility will enable customers to qualify new platforms with confidence across extended product lifecycles.
Strategic Context: Project Quantum Leap and Market Growth
Shifting from M&A to Organic Investment
Founded in 1887 and reporting $3.5 billion in revenue in 2025, H.B. Fuller operates in 150 countries with approximately 7,100 employees. Historically, the company has built its aerospace and engineering adhesives portfolio through strategic Acquisitions, including the purchase of Royal Adhesives & Sealants in 2017 and ND Industries in May 2024.
However, industry reports indicate that in early 2026, H.B. Fuller announced a temporary pause on mergers and acquisitions to focus on share repurchases and debt reduction. Consequently, organic investments like the Charlotte facility are now the primary vehicle for capturing high-margin growth. During the company’s Q1 2026 earnings call, CEO Celeste Mastin noted that the redesigned plant and supply chain network under Project Quantum Leap will strengthen long-term competitiveness and deliver improved profitability.
The Booming Aerospace Adhesives Market
The investment in North Carolina aligns with robust growth projections for the aerospace adhesives sector. According to market research from Future Market Insights (FMI), the global aerospace adhesives and sealants market is projected to reach $1.11 billion in 2026 and expand to $1.83 billion by 2036, representing a 5.1 percent Compound Annual Growth Rate (CAGR). Other research firms, such as SNS Insider, estimate the market could reach $2.37 billion by 2035.
This growth is primarily driven by the aerospace industry’s demand for lightweight materials to improve fuel efficiency and reduce emissions. Adhesives are increasingly substituting traditional mechanical fasteners in airframe assembly, engine nacelle construction, and cabin interiors because they provide superior load distribution and bond diverse composite materials effectively. North America currently dominates this space, capturing over 40 percent of the global market share in 2025, supported heavily by U.S. military spending and commercial original equipment manufacturer (OEMs) production.
AirPro News analysis
We view H.B. Fuller’s decision to locate its new Center of Excellence in Charlotte as a highly strategic geographic play. North Carolina is currently recognized as the second fastest-growing aerospace industry in the United States, home to over 400 aerospace providers and more than 200 aerospace companies.
By placing its most advanced manufacturing hub in this corridor, H.B. Fuller taps into a highly localized ecosystem where 60 percent of supply chain purchases are made in-state. With major next-generation aviation investments occurring nearby, such as JetZero’s planned flagship manufacturing plant in Greensboro, H.B. Fuller is positioning itself within a critical supply radius for future airframe production. Furthermore, by pivoting from acquisitions to optimizing its own footprint, the company is demonstrating a mature approach to margin expansion that capitalizes on the industry’s irreversible shift toward composite bonding.
Frequently Asked Questions (FAQ)
What is the new H.B. Fuller facility?
H.B. Fuller is building a new Aerospace Manufacturing Center of Excellence to consolidate its specialized manufacturing, packaging, testing, and quality operations for the aviation, space, and defense markets.
Where will the facility be located and when will it open?
The facility will be located in Charlotte, North Carolina, and is expected to begin operations in early 2027.
Why are adhesives growing in the aerospace sector?
Aerospace manufacturers are increasingly using advanced adhesives instead of traditional mechanical fasteners to bond lightweight composite materials. This reduces the overall weight of the aircraft, which improves fuel efficiency and lowers emissions.
What is Project Quantum Leap?
It is an enterprise-wide restructuring and operational excellence program by H.B. Fuller aimed at optimizing its global footprint, reducing costs, and concentrating resources on high-margin segments.
Sources: H.B. Fuller Company Press Release
Photo Credit: H.B. Fuller
MRO & Manufacturing
StandardAero Expands Component Repair Services with Unified Turbines Acquisition
StandardAero acquires Unified Turbines to enhance hot section repairs for Pratt & Whitney and Honeywell turboprop engines, boosting CRS capabilities.
This article is based on an official press release from StandardAero.
StandardAero has officially announced its acquisitions of Unified Turbines, LLC, a strategic move designed to bolster its Component Repair Services (CRS) segment. The all-cash transaction marks a significant expansion of StandardAero’s capabilities in hot section component repair and overhaul for key turboprop engine platforms.
According to the company’s press release, this purchase represents StandardAero’s 14th acquisition since 2015 and its eighth specifically within the CRS division. By bringing a long-time vendor in-house, the aerospace engine aftermarket services provider aims to streamline its supply chain and enhance turnaround times for its global customer base.
Expanding Turboprop Engine Capabilities
A Strategic Addition to the CRS Segment
Unified Turbines, founded in 1997 and operating out of an FAA Repair Station in Milton, Vermont, specializes in hot section component repairs. The company primarily services Pratt & Whitney and Honeywell engines, which power a wide array of regional and business aircraft. These include popular platforms such as the King Air, Cessna Caravan, Pilatus PC-12, ATR 42 and 72, and De Havilland DASH 7 and 8.
StandardAero noted in its press release that Unified Turbines has been a high-performing vendor for the company since 2001. The integration of Unified Turbines will directly support StandardAero’s existing market leadership on Pratt & Whitney’s PT6A and PW100 turboprop engine families.
Leadership Perspectives on the Acquisition
The acquisition is expected to create highly synergistic benefits for StandardAero’s Engine Services segment. By leveraging faster component repair turnaround times, the company intends to deliver more efficient solutions to its clients.
“Unified Turbines represents a strategic addition to StandardAero and supports our commitment to disciplined, value‑accretive growth. This acquisition expands our capabilities on several key turboprop platforms where we already serve a large global customer base, while strengthening the technical depth we deliver across our MRO network.”
Integration and Future Outlook
Alignment with Core Growth Drivers
Organizationally, Unified Turbines will be integrated into StandardAero’s Component Repair Services segment. This division is described by the company as a core driver of strategic growth, boasting a portfolio of more than 20,000 unique repairs across commercial, military, helicopter, and aeroderivative engines.
The all-cash transaction underscores StandardAero’s ongoing strategy of targeted acquisitions to build out its specialized maintenance, repair, and overhaul (MRO) capabilities. While the specific financial terms of the deal were not disclosed in the announcement, the move clearly signals a continued focus on vertical integration within the aerospace aftermarket sector.
AirPro News analysis
We view the acquisition of Unified Turbines by StandardAero as indicative of a broader industry trend where major MRO providers are actively consolidating their supply-chain. By acquiring a trusted vendor of over two decades, StandardAero not only secures critical repair capabilities for high-demand engines like the PT6A and PW100 but also mitigates potential supply chain bottlenecks. As the regional turboprop market continues to see steady utilization, we believe that bringing hot section repair expertise in-house will likely provide StandardAero with a competitive edge in controlling costs and improving service delivery times.
Frequently Asked Questions
What is Unified Turbines, LLC?
Unified Turbines is an FAA Repair Station based in Milton, Vermont, founded in 1997. It specializes in hot section component repair and overhaul services for Pratt & Whitney and Honeywell engines.
How many acquisitions has StandardAero made recently?
According to the official press release, the purchase of Unified Turbines is StandardAero’s 14th acquisition since 2015 and its eighth within the Component Repair Services segment.
Which aircraft platforms will benefit from this acquisition?
The acquisition enhances repair capabilities for engines powering aircraft such as the King Air, Cessna Caravan, Pilatus PC-12, ATR 42 and 72, and De Havilland DASH 7 and 8.
Sources
Photo Credit: Montage AirPro News – StandardAero
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