MRO & Manufacturing
Sonex Aircraft Reopens as Sonex Aviation After Acquisition in 2026
Sonex Aircraft reopens as Sonex Aviation after ON Capital acquisition, resuming production and honoring customer orders in 2026.
This article is based on an official press release from Sonex Aircraft, supplemented by industry reporting.
Sonex Aircraft, a cornerstone manufacturers in the experimental and homebuilt aircraft community based in Oshkosh, Wisconsin, has officially reopened its doors under the new name “Sonex Aviation” as of May 1, 2026. This rapid revival comes just over a month after the company shocked the aviation world with a sudden closure announcement.
According to an official company press release, the manufacturer’s assets, including the Sonex Aerospace and AeroConversions product lines, were acquired by ON Capital, Inc. The acquisition successfully recapitalized the business, allowing production to resume immediately and saving the beloved kit manufacturer from bankruptcy proceedings.
The swift 21-day turnaround from the initial closure to the finalization of the acquisition brings immense relief to builders and customers with unfulfilled orders. With the factory lights back on, the company is prioritizing its backlog, particularly for the highly anticipated Sonex High Wing model, while restructuring its leadership to focus on future innovation.
The Acquisition and New Leadership
A Swift Rescue by ON Capital
The rescue of Sonex was spearheaded by Stephen Osborne, the head of ON Capital, Inc. Osborne brings a deep, personal connection to grassroots aviation. According to the company’s release, he is a lifetime Experimental Aircraft Association (EAA) member, a third-generation aviator, a warbird pilot, a flight-school owner, and a general contractor. His diverse background in both business management and aviation positioned him to quickly assess and acquire the struggling manufacturer.
Osborne emphasized his commitment to the brand’s legacy and its role in the broader aviation ecosystem in a public statement:
“My family has flown for three generations; its an absolute honor to carry on the proud legacy of the Sonex brand. Sonex is part of how this country builds pilots and how everyday people get into the sky. Letting it disappear was never an option. To every customer with a deposit on the books – get your shop space ready. We are open, we are building, and your kit is coming.”
— Stephen Osborne, Owner, Sonex Aviation
The transition has also received the blessing of the company’s original creator. John T. Monnett, Jr., the founder of Sonex Aircraft, expressed his confidence in the new ownership, stating in the press release that Osborne’s team possesses “the capital, the conviction, and the love of flight to take Sonex further than it has ever been.”
Production Resumes and Orders Honored
Fulfilling the Backlog
One of the most pressing concerns following the March closure was the status of customer deposits. Under the new Sonex Aviation banner, Osborne has publicly pledged to honor all existing customer deposits. The Oshkosh factory is currently operational, with crews actively working to clear the accumulated backlog. Company officials expect the facility to reach full production capacity within the next few weeks.
The Sonex High Wing and Leadership Shifts
A major focal point for the newly recapitalized company is the Sonex High Wing. According to production updates provided by the company, there are currently 80 pre-orders on the books for this new model. Sonex Aviation anticipates that tail kits will resume shipping in May 2026, with full kits expected to begin shipping by mid-summer.
To ensure the continued refinement of these kits, former owner and CEO Mark Schaible has been retained by the new ownership. Transitioning to the role of Lead Designer, Schaible is now freed from the day-to-day administrative and financial burdens that previously consumed his time. The company notes that he will now focus exclusively on aircraft design, kit refinement, and providing direct support to builders and pilots.
Contextualizing the March Closure
Financial Pressures and Market Shifts
The triumphant reopening stands in stark contrast to the bleak outlook presented just weeks prior. On March 27, 2026, Mark Schaible released a video message announcing the immediate shutdown of Sonex LLC. The closure halted all operations and pushed both the business and Schaible’s personal finances into bankruptcy proceedings.
At the time, Schaible attributed the failure to an insurmountable combination of economic factors.
“We’ve had to make this decision very suddenly as a perfect storm of bank pressure, lack of sales, increasing costs, competition from our own aircraft in the used market, and cashflow realities are not allowing us to continue our work.”
— Mark Schaible, speaking on March 27, 2026
AirPro News analysis
While internal cashflow and rising operational costs were the immediate catalysts for Sonex’s March collapse, broader regulatory and market shifts played a significant underlying role. As reported by Forbes in late March, the FAA‘s new MOSAIC (Modernization of Special Airworthiness Certification) rule likely contributed to the financial strain on traditional light sport aircraft (LSA) manufacturers.
By expanding regulations to allow entry-level sport pilots to operate heavier, four-seat legacy aircraft like the Cessna 172, the MOSAIC rule inadvertently chilled the market for traditional two-seat kitplanes. We observe that many prospective builders and buyers paused their purchasing decisions, waiting to see what new four-seat options would become viable under the updated regulations. This hesitation directly impacted sales for companies like Sonex, which rely on a steady stream of kit orders to maintain cash flow.
Furthermore, the experimental aircraft market has been experiencing a period of notable instability. The recent high-profile bankruptcy and reorganization of Van’s Aircraft, the largest player in the kitplane industry, highlighted the fragile margins within the sector. However, the rapid 21-day rescue of Sonex Aviation underscores the remarkable resilience and brand loyalty within the grassroots aviation community. With an estimated 1,600 kits sold historically, Sonex remains a vital pipeline for affordable aircraft ownership, and its survival is a positive indicator for the homebuilt market’s endurance.
Frequently Asked Questions
What is the new name of the company?
Following the acquisition by ON Capital, Inc., the company has been slightly rebranded and is now operating as Sonex Aviation.
Will my existing deposit be honored?
Yes. New owner Stephen Osborne has explicitly stated that all existing customer deposits on the books will be honored, and kits are currently being prepared for shipment.
When will the Sonex High Wing kits ship?
According to the company, tail kits for the Sonex High Wing are scheduled to ship in May 2026, with full kits expected to follow by mid-summer 2026.
Sources:
Photo Credit: Sonex Aircraft
MRO & Manufacturing
DART Aerospace FAA Certification for Cable Cutter on Airbus H145 BK117 D-3
DART Aerospace received FAA approval for its Cable Cutter system on the Airbus H145 BK117 D-3, enhancing wire strike protection for rotorcraft operators.
This article is based on an official press release from DART Aerospace.
On May 5, 2026, DART Aerospace announced the receipt of an updated Federal Aviation Administration (FAA) Supplemental Type Certificate (STC). According to the company’s press release, this certification officially approves the installation of its extended Cable Cutter system on the Airbus H145 BK117 D-3 helicopter.
Wire strikes remain one of the most significant hazards for low-flying rotorcraft, particularly those engaged in Helicopter Emergency Medical Services (HEMS), search and rescue (SAR), and utility operations. By securing this STC, DART Aerospace provides operators of the advanced five-blade H145 variant with a critical, passive safety mechanism designed to prevent catastrophic mid-air collisions with power lines and cables.
We note that this certification expands DART’s existing portfolio of wire-strike protection systems, which already covered earlier iterations of the H145 family, ensuring that modern fleets can maintain rigorous safety standards as they upgrade their aircraft.
Engineering the Cable Cutter System
Passive Protection for High-Risk Missions
The DART Cable Cutter system operates as a passive safety device. As detailed in the provided research report, the system features both upper and lower cutters equipped with high-strength blades. Deflectors are integrated into the design to guide unseen wires away from the windshield and rotor hub, funneling them directly into the cutting mechanism.
The engineering behind the system is robust. Testing verifies that the DART cutter can sever cables with a tensile strength of up to 14,000 lbs. The primary objective is to stop wires from breaching the cockpit or entangling the main and tail rotor flight controls.
“The primary goal is to prevent catastrophic damage by stopping wires from entering the cockpit,” according to the provided industry research report.
The Airbus H145 BK117 D-3 Platform
Expanding Capabilities for Modern Fleets
The Airbus H145, specifically the BK117 D-3 variant, is a premier aircraft in the light twin-engine category. The D-3 model is distinguished by its innovative five-blade main rotor system, which Airbus designed to provide a smoother flight experience and an additional 150 kg (approximately 330 lbs) of useful load capacity compared to its predecessors.
Because of its compact footprint and rear clamshell doors, the H145 D-3 is heavily utilized globally for air ambulances, law enforcement, and offshore energy transport. Prior to this May 2026 update, DART’s cable cutter STC already covered older variants in this family, including the Airbus H145 / EC145 T2 and the BK117 D-2, according to the company’s background data.
The Deadly Threat of Wire Strikes
Industry Statistics and Safety Imperatives
Helicopters frequently operate at low altitudes, often below 500 feet, where power lines, telephone wires, and guy-wires present a nearly invisible threat to pilots, especially against complex terrain or in poor lighting conditions.
Data from the National Transportation Safety Board (NTSB) highlights the severity of this hazard, recording 124 fatalities in the United States attributed to wire strikes between 1994 and 2018. Furthermore, aerospace medical studies cited in the research report indicate that in fatal wire strikes, 100% of victims suffered major head and neck injuries, frequently sustaining basilar skull fractures due to impact with flight controls.
AirPro News analysis
At AirPro News, we view the continuous updating of STCs by aftermarket manufacturers like DART Aerospace as a vital component of the aviation safety ecosystem. As Original Equipment Manufacturers (OEMs) like Airbus innovate, such as introducing the five-blade rotor on the D-3, third-party safety equipment must keep pace. The rigorous FAA STC process ensures that these retrofits do not compromise the airworthiness of modern, highly advanced airframes. For global operators, the availability of a 14,000-lb capable cable cutter for the newest H145 variant is not just a regulatory checkbox; it is a life-saving necessity that turns potentially fatal collisions into recoverable incidents.
Frequently Asked Questions (FAQ)
What is an FAA STC?
A Supplemental Type Certificate (STC) is a document issued by the FAA approving a major modification or repair to an existing type-certified aircraft. It signifies that the FAA has thoroughly reviewed the engineering and safety of the modification.
What is the tensile strength capacity of the DART Cable Cutter?
According to the company’s specifications, the DART Cable Cutter system is tested and verified to cut through cables with a tensile strength of up to 14,000 lbs.
Who is DART Aerospace?
DART Aerospace is a privately held manufacturer of helicopter equipment and aftermarket accessories. The company has been in operation for 50 years, holds over 2,000 STC certifications, and ships roughly 30,000 parts annually to 120 countries.
Sources
Photo Credit: DART Aerospace
MRO & Manufacturing
Lindo and Airbus Collaborate on Antimicrobial Blue Light for HEMS
Lindo and Airbus partner to develop antimicrobial blue light disinfection technology for Helicopter Emergency Medical Services in Australia and Asia Pacific.
This article is based on an official press release from Lindo.
Lindo has officially announced a new collaboration with Airbus Asia Pacific and Airbus Helicopters, marked by the signing of a Memorandum of Understanding (MoU). The agreement centers on the exploration and development of antimicrobial blue light (aBL) applications specifically designed for Helicopter Emergency Medical Services (HEMS).
According to the official statement released by Lindo, this partnership establishes a strategic framework to investigate the integration of occupant-safe disinfection technologies into next-generation aeromedical platforms. The initiative is positioned to support future HEMS programs throughout Australia and the broader Asia Pacific region.
At the heart of this collaboration is a focus on infection prevention. Critical care transport environments operate under intense time pressures and experience high patient turnover, creating inherent risks for pathogen transmission that both companies are now seeking to mitigate.
Advancing Aeromedical Disinfection Technology
Helicopter Emergency Medical Services face unique operational challenges. The confined spaces of aeromedical cabins require rigorous cleaning protocols between missions, which can impact turnaround times and operational efficiency. By introducing antimicrobial blue light technology, Lindo and Airbus aim to provide a continuous, autonomous layer of protection.
In their public announcement, Lindo emphasized the operational and safety benefits of this technological leap for healthcare transport environments.
“Advancing autonomous, continuous disinfection within these settings represents a meaningful step toward reducing pathogen transmission while maintaining operational efficiency,” stated Lindo in their official release.
Research, Development, and Future Integration
Phased Approach to Certification
The collaboration will initially prioritize research and development. According to the company’s statement, the early phases of the project will focus on feasibility studies, system integration, and the rigorous validation of antimicrobial lighting solutions within Airbus helicopter platforms.
Following the successful completion of these R&D milestones, the partnership intends to map out potential pathways for certified integration into operational aircraft, ensuring the technology meets stringent aviation safety and regulatory standards.
Collaborative Innovation and Support
This MoU represents a significant alignment of global aerospace capabilities with Australian technological innovation. The technical execution from Lindo’s side is being driven by their internal R&D team, including Urbain du Plessis, in conjunction with their design partners at Marker Design.
The initiative has also garnered regional backing. Lindo acknowledged the continued support of the Victorian Government in enabling advanced manufacturing and technology development within the state. The company publicly thanked key government representatives, including Gönül Serbest, Teresa Tufano, and Chin Wijesuriya, alongside Airbus personnel Christian Venzal, Scott White, Andrew Wild, Richard Ward, and Mandy Hentschel for their roles in supporting the MoU.
AirPro News analysis
We view this MoU as a highly relevant development in the evolution of aeromedical transport. The global healthcare sector has placed an increased premium on passive, continuous disinfection technologies in the wake of recent global health challenges. Antimicrobial blue light (aBL) is particularly notable because, unlike traditional UV-C light, specific wavelengths of aBL can be deployed safely in the presence of human occupants. If Lindo and Airbus successfully navigate the complex aviation certification pathways, this technology could establish a new baseline for cabin safety and infection control in future HEMS fleets worldwide.
Frequently Asked Questions (FAQ)
What is the primary focus of the Lindo and Airbus MoU?
The agreement focuses on exploring and integrating antimicrobial blue light (aBL) disinfection applications into Helicopter Emergency Medical Services (HEMS).
Which regions will benefit from this collaboration?
The framework is designed to support future HEMS programs across Australia and the broader Asia Pacific region.
Who is involved in the research and development?
The R&D is being led by Lindo’s internal team and Marker Design, with integration support from Airbus Helicopters and advanced manufacturing backing from the Victorian Government.
Sources
Photo Credit: Lindo – LinkedIn
MRO & Manufacturing
Boeing Proposes Fix for Grounded MD-11 Fleet with FedEx Return Plan
Boeing developed a hardware fix for the grounded MD-11 fleet after a fatal 2025 crash. FedEx plans test flights in May 2026 pending FAA approval.
Boeing has developed a hardware fix and comprehensive maintenance plan for the grounded McDonnell Douglas MD-11 freighter fleet, potentially paving the way for FedEx to return the aircraft to the skies by the end of May 2026. The global fleet has been grounded for six months following a fatal crash in late 2025 that prompted emergency regulatory action.
According to reporting by The Seattle Times, the proposed engineering solution involves replacing specific bearings within the aircraft’s engine pylons. While rival cargo carrier UPS Airlines opted to permanently retire its MD-11 fleet following the tragedy, FedEx, the world’s largest operator of the type, has worked closely with Boeing to engineer a recovery plan for its widebody tri-jets.
The Federal Aviation Administration (FAA) is currently reviewing Boeing’s compliance data. If regulators approve the procedures, the fix will close a highly disruptive and costly chapter for FedEx, which absorbed significant financial penalties to maintain its global cargo network during the peak holiday shipping season without the high-capacity freighters.
The Catalyst and the Grounding
The Louisville Tragedy
The grounding of the MD-11 fleet stems from the November 4, 2025, crash of UPS Airlines Flight 2976. According to investigative reports summarized by The Seattle Times, the aircraft’s left engine detached from the wing during takeoff from Louisville International Airport in Kentucky. The resulting crash resulted in the deaths of the three occupants onboard, as well as innocent bystanders on the ground.
Subsequent investigations by the National Transportation Safety Board (NTSB) identified severe distress and fatigue cracks in the left pylon of the widebody aircraft, specifically isolating failures in the aft mount lug and spherical bearing. In response to these findings, the FAA issued an emergency airworthiness directive in mid-November 2025, prohibiting all MD-11 flights until thorough inspections and corrective actions could be implemented.
Diverging Airline Strategies
The grounding forced the two primary operators of the MD-11 to make drastically different strategic decisions. The Seattle Times reports that UPS Airlines announced in January 2026 it would permanently scrap its fleet of 27 MD-11s, absorbing a $137 million financial charge in the process.
Conversely, FedEx expressed optimism regarding a mechanical resolution. Within a week of the Louisville crash, FedEx shared detailed maintenance records with Boeing to assist engineers in developing a viable hardware fix for its 58-aircraft fleet.
Boeing’s Proposed Hardware Fix
Engineering a Solution
Boeing’s proposed remedy centers on a targeted hardware replacement rather than a complete structural overhaul. The Seattle Times notes that the fix requires installing newly redesigned Boeing bearings in the aft mount of each side pylon, paired with a rigorous inspection of the aft bulkhead.
Boeing has reportedly completed its engineering analysis and submitted its means of compliance to the FAA. The aviation industry is currently waiting for regulators to issue the final paperwork.
“…final, FAA-approved procedures.”
— Industry status regarding the Boeing fix, as quoted by The Seattle Times.
FedEx’s Massive Return-to-Service Operation
Global Logistics and Timeline
Anticipating FAA approval, FedEx has initiated a massive logistical operation to prepare its fleet for reactivation. According to The Seattle Times, the cargo giant is dispatching specialized technicians to 16 global locations to physically remove the wing-mounted engine pylons from 29 grounded MD-11 freighters. These massive components are being shipped to heavy maintenance facilities in Memphis, Tennessee, and Indianapolis, Indiana, where the new Boeing bearings will be installed.
During a company-wide town hall on May 6, 2026, FedEx leadership briefed employees on the reactivation timeline. The carrier plans to conduct two test flights in the first half of May, with the goal of resuming broader commercial operations by the end of the month. Because the fleet has been parked for half a year, FedEx is also requiring its MD-11 pilots to complete a three-day refresher training course to ensure operational readiness.
Financial and Strategic Stakes
The economic imperative for FedEx to return the MD-11 to service is substantial. The Seattle Times reports that the sudden loss of capacity during the peak holiday season forced FedEx to rely on its ground network, pilot overtime, and expensive third-party commercial airlift partners. These contingency measures cost the company $175 million during its third quarter.
Reactivating the fleet will allow FedEx to terminate costly wet-lease agreements. Furthermore, the aircraft remains central to FedEx’s long-term strategy; in March 2025, the company extended the retirement deadline for its MD-11 fleet from 2028 to 2032 to capture rising demand for heavy, industrial cargo shipments.
Regulatory and Political Hurdles
FAA Scrutiny and Political Pushback
Despite FedEx’s logistical preparations, the final decision rests with regulators. The FAA has maintained a strict public stance, reiterating that the aircraft will remain grounded until the entire fleet is inspected and the proposed fixes are fully certified.
The aircraft also faces intense political scrutiny. Congressman Morgan McGarvey has publicly urged regulators to permanently ground the 1990s-era tri-jet, citing severe safety concerns stemming from the deadly Louisville crash.
AirPro News analysis
We observe that the contrasting decisions between UPS and FedEx highlight a broader tension in the air cargo market: the delicate balance between safety optics and raw economic necessity. FedEx’s willingness to absorb a $175 million quarterly penalty and execute a highly complex, global pylon-removal operation underscores a severe lack of immediate widebody freighter alternatives in the current market. While UPS chose to cut its losses and modernize, FedEx’s prior decision to extend the MD-11’s lifespan to 2032 means the company is heavily reliant on the aircraft’s unique payload capabilities. Moving forward, FedEx will likely face an uphill battle in public relations, as it must convince both its crew members and the public that a decades-old airframe is safe to fly following a catastrophic structural failure.
Frequently Asked Questions
Why was the Boeing MD-11 grounded?
The FAA grounded the global MD-11 fleet in November 2025 after a UPS Airlines freighter crashed in Louisville, Kentucky. The NTSB discovered fatigue cracks in the left engine pylon’s aft mount lug and spherical bearing, which caused the engine to detach during takeoff.
What is Boeing’s proposed fix for the MD-11?
According to reporting by The Seattle Times, Boeing’s solution involves replacing specific hardware, installing newly redesigned bearings in the aft mount of each side pylon, alongside a thorough inspection of the aft bulkhead.
When will FedEx resume flying the MD-11?
FedEx plans to conduct test flights in the first half of May 2026 and aims to gradually return the aircraft to broader commercial service by the end of May, pending final FAA approval.
Sources: The Seattle Times
Photo Credit: FedEx
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