Leonardo officially opened a new 6,000-square-metre building dedicated to the development and manufacture of Helicopters flight simulators in Sesto Calende, Italy, on October 5, 2026. The facility expansion consolidates the site as a central development and production hub for simulation systems across the company’s rotary-wing business.

In a press release issued to mark the opening, Leonardo highlighted the financial weight of its Customer Support, Services & Training segment. Between 2023 and 2025, this division accounted for an average of 42 percent of total revenues for Leonardo Helicopters, underscoring the strategic importance of aftermarket and synthetic training solutions.

Expanding simulation capabilities

The newly inaugurated building provides the physical space required to design, assemble, and test complex synthetic training devices. According to Leonardo, the facility can accommodate up to five full-flight simulators at a single time. The first simulators manufactured in the new building are slated for delivery to helicopter operators based in Italy and Asia-Pacific, supporting both domestic and international training requirements.

Simulator design and manufacturing represent established core competencies at the Sesto Calende site. Leonardo has previously developed specialized training systems for military operators, tailoring simulators to specific mission profiles. These include the A129 Mangusta simulator for Italian Army Aviation in Viterbo, the HH139 simulator for the Italian Air Force in Cervia, and the NH90 simulator located at the Italian Navy’s Maristaeli Luni simulation centre. The expanded footprint allows the manufacturer to increase its independent development capabilities while continuing to support established partnerships across the defense and civil sectors.

Sesto Calende’s century of aviation history

The Sesto Calende site serves as the main headquarters for customer support within the Leonardo Helicopter Division. The location possesses an aviation heritage dating back to 1915, anchoring the company’s long-term industrial presence in the region. In 2006, Leonardo opened the “A. Marchetti” Training Academy at the site, establishing its first dedicated helicopter training academy to centralize pilot and maintenance instruction.

The facility also hosts RotorSim, a joint venture established with CAE that provides synthetic training solutions for rotary-wing operators. To support the growing demand for training and simulation, Leonardo has steadily increased its workforce at the location. Employee headcount at the Sesto Calende facility stood at approximately 470 in 2022. By 2025, that number had grown by 30 percent to reach over 610 personnel. Across all of its global helicopter training activities, Leonardo reports that it trains 16,000 people annually, a volume that requires continuous investment in physical infrastructure and simulation technology.

The financial weight of training and support

Training and support services represent highly lucrative segments for aerospace original equipment manufacturers. By expanding its physical infrastructure for simulator production, Leonardo is positioning itself to capture a larger share of the aftermarket revenue generated by its global helicopter fleet. The 42 percent revenue share generated by the Customer Support, Services & Training segment between 2023 and 2025 highlights the financial stability provided by long-term service contracts and recurrent training mandates.

The demand for Leonardo’s rotary-wing products remains active in the broader market, ensuring a steady pipeline of operators requiring simulation services. In early October 2026, GD Helicopter Finance secured a EUR 125 million facility to finance new Airbus and Leonardo helicopter deliveries. The continued influx of new airframes into the commercial and parapublic markets directly drives the requirement for initial type ratings and recurrent simulator training, reinforcing the business case for the Sesto Calende expansion.

AirPro News analysis

We view the Sesto Calende expansion as a clear indicator of where aerospace manufacturers are finding reliable margins. With Customer Support, Services & Training generating 42 percent of Leonardo’s helicopter revenues, the division is no longer just a supporting function for airframe sales. By bringing more simulator development and manufacturing in-house, Leonardo reduces its reliance on third-party simulation providers and captures the full lifecycle value of its aircraft platforms. This vertical integration strategy ensures that as the global fleet grows, the high-margin training revenue flows directly back to the original equipment manufacturer.

Textron Aviation has launched Kansas’ first state-registered aviation youth apprenticeship program, creating a paid, multi-year training pathway for high school students starting at age 16. The initiative aims to build a localized workforce pipeline for the aerospace manufacturer by integrating classroom education with hands-on technical experience.

Announced in a press release on September 30, 2026, the program operates in collaboration with the Kansas Office of Apprenticeships, WSU Tech, and Tri County Tech. The first cohorts of students began their training in the fall of 2026, entering specialized tracks designed to address the aviation industry’s growing demand for skilled maintenance and manufacturing professionals.

Program structure and educational partnerships

The youth apprenticeship initiative encompasses three distinct technical tracks distributed across two Kansas facilities. In Wichita, students can pursue Airframe & Powerplant (A&P) or Avionics disciplines through a partnership with WSU Tech. In Independence, Kansas, the program offers an Engine Buildup track in collaboration with Tri County Tech.

The curriculum was developed alongside several regional educational institutions to align high school graduation requirements with industry technical standards. Participating schools include Wichita Public Schools, Haysville Public Schools, Kapaun Mt. Carmel Catholic High School, and Dewey High School in neighboring Oklahoma.

Students entering the program engage in structured skill development that spans up to three years. Upon completion, participants earn a recognized credential through the Kansas Office of Apprenticeships, positioning them for immediate employment in the aerospace sector or further technical education.

Maggie Topping, Senior Vice President of Human Resources and Communications at Textron Aviation, stated that the program is designed to introduce students to the aerospace sector before they finalize their post-secondary plans.

“The youth apprenticeship program is about opening the door earlier for students who can see themselves building a future in aviation. By working with our education and workforce partners, we’re helping students gain meaningful experience, build confidence and develop the skills our industry needs for the future,” Topping said.

Expanding the aerospace workforce pipeline

The aviation manufacturing and maintenance sectors face a sustained demand for skilled labor. Aerospace original equipment manufacturers (OEMs) and maintenance, repair, and overhaul (MRO) providers are increasingly turning to apprenticeship models to secure a long-term workforce. By connecting education directly with industry requirements, companies can train workers on specific equipment and procedures while students are still completing their secondary education.

State officials view the integration of registered apprenticeships into high schools as a critical economic development tool. The Kansas Office of Registered Apprenticeship has supported the expansion of these programs across multiple industries, with aviation representing a major component of the state’s manufacturing base.

“We already are seeing positive results in other sectors when Kansas employers bring Registered Apprenticeship directly to high school students,” said Shonda Anderson, Director of the Kansas Office of Registered Apprenticeship. “Textron Aviation is leading the way in aviation and advanced manufacturing, giving young Kansans the opportunity to earn while they learn, and building the skills they need for high-wage, in-demand careers right here in Kansas. This is more than preparing students for the future – it’s connecting youth with great aviation careers right now.”

Educational partners also emphasized the dual benefits of the earn-and-learn model. Dr. Sheree Utash, President of WSU Tech, noted that the direct path into high-demand careers serves the interests of both the students and the broader regional economy, describing the initiative as a direct path into high-demand aviation careers.

Textron Aviation’s history of workforce investments

The launch of the youth apprenticeship program follows several years of targeted workforce development initiatives by Textron Aviation. The company, a subsidiary of Textron Inc., is a major aerospace manufacturer responsible for the Cessna, Beechcraft, and Pipistrel brands. Its product portfolio spans business jets, turboprops, light and high-performance pistons, as well as special mission and military trainer aircraft. According to the company, Textron Aviation has produced more than half of all general aviation aircraft worldwide and supports a customer base spread across more than 170 countries.

To support its production rates and global operations, Textron Aviation launched its first state-registered adult apprenticeship cohort in August 2023. That inaugural group included two paint apprentices and eight maintenance apprentices. The cohort completed their training and earned certificates of completion in August 2025.

The success of the initial adult program attracted state-level financial support. In late 2025, Kansas Governor Laura Kelly announced that Textron Aviation was one of 12 businesses selected to receive a portion of a $535,000 state grant. The funding was specifically allocated to expand registered apprenticeship programs across Kansas. Textron Aviation utilized the grant to grow its A&P apprenticeships in collaboration with WSU Tech, a development the company highlighted in May 2026.

The first cohorts of the new youth program are expected to complete their structured skill development by 2029. The initiative represents a structural shift in how aerospace manufacturers in the region recruit and train technical talent, moving the point of entry earlier in the educational timeline to secure the next generation of aviation professionals.

The United States Air Force (USAF) Air Education and Training Command (AETC) has successfully executed its inaugural Live-Virtual-Constructive (LVC) flight, linking an airborne Boeing T-7A Red Hawk directly with ground-based simulators.

The September 16, 2026, milestone at Joint Base San Antonio-Randolph validates the digital architecture required to train future combat aviators. The integration allows live aircraft and synthetic environments to share a common operating picture in real time, eliminating the logistical expense of fielding physical adversary aircraft. The achievement was detailed in an AETC press release.

Fusing live flight with synthetic battlespaces

The operation involved instructor pilots from the 99th Flying Training Squadron (99th FTS), including unit commander Lt. Col. Michael Trott and operations officer Lt. Col. Phillip Bourquin, working alongside civilian simulator instructors from the 12th Training Squadron (12th TRS). The flight utilized a T-7A aircraft designated APT-4 and the T-7A Ground-Based Training System (GBTS).

The LVC technology enables ground-based simulators to communicate directly with airborne aircraft via secure, high-bandwidth tactical data links. This capability allows instructors to inject constructive threats, such as surface-to-air missile rings and electronic warfare jamming, directly into the cockpit displays of the live aircraft.

Robb Erickson, a retired Air Force colonel and the T-7A Civilian Simulator Instructor Lead for the 12th TRS, highlighted the operational shift.

“When APT-4 took flight, we weren’t just flying another training sortie. We established a live, bidirectional data link fusing an airborne aircraft directly into our simulators and synthetic battlespace,” Erickson stated.

The successful flight confirms the core digital architecture of the training system. Erickson noted that proving the aircraft and simulators can communicate and fight together in the same virtual sky keeps the program on track to deliver cutting-edge training. He added that the power of LVC lies in its density, complexity, and interconnectivity. By tethering simulators directly to the live aircraft in the airspace, student pilots can experience the realistic, sensor-saturated operational environment they will face in front-line fighters and other combat aircraft.

Ryan Sparkman, a retired Air Force lieutenant colonel and civilian simulator instructor with the 12th TRS, emphasized the contrast with previous training methods. According to Sparkman, the synthetic injection challenges aircrews with threat presentations and sensor-management puzzles that were impossible to replicate on legacy flying platforms.

The Boeing T-7A Red Hawk transition

The T-7A Red Hawk is an advanced pilot training system designed to replace the aging fleet of T-38 Talon trainers. The legacy T-38 has been in service for approximately 65 years, necessitating a modernization effort to prepare pilots for fifth- and sixth-generation fighters. The digitally designed T-7A features an open architecture digital fly-by-wire control system and modern avionics.

The USAF plans to acquire 351 T-7A jets to provide training for future fighter and bomber pilots. The Boeing Company delivered the first T-7A jet, designated APT-5, to the USAF on December 5, 2025. The aircraft was officially inducted into AETC service at Joint Base San Antonio-Randolph on January 12, 2026. The 12th Flying Training Wing, based at the installation, is currently preparing for the arrival of the full production fleet.

The September 16 flight builds on earlier connectivity tests conducted during the development phase. On September 24, 2025, Boeing software engineers in St. Louis successfully tested connectivity between a ground-based simulator and an in-flight T-7A flying 130 miles away.

Preparations for the broader rollout of the training system are advancing alongside the technical milestones. On September 28, 2026, Boeing announced that the first class of seven contract instructor pilots completed a 31-day T-7A Red Hawk simulator course at Joint Base San Antonio-Randolph. This completion establishes the foundational instructor base required to operate the new training system.

AirPro News analysis

The successful demonstration of LVC capabilities within the T-7A program represents a fundamental change in military flight training economics and security. By tethering simulators directly to live aircraft, the USAF can generate complex, sensor-saturated environments without the prohibitive cost of launching multiple adversary aircraft. This density and interconnectivity are critical for preparing student pilots for the operational realities of front-line combat aircraft.

Beyond cost savings, the LVC architecture addresses a growing operational security requirement. Training against advanced constructive threats in a secure, synthetic environment prevents adversaries from observing physical aircraft executing classified tactics or reacting to specific electronic warfare profiles in open airspace. As the USAF prepares to field its next generation of combat aircraft, the ability to simulate high-end threats digitally will be as critical as the aerodynamic performance of the trainer itself. We view the successful integration of the GBTS with live flight operations as a critical de-risking event for the broader T-7A procurement strategy.