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West Star Aviation Posts 84% AOG Rate After DCJet Acquisition

West Star Aviation achieved a record 84% AOG acceptance rate in May 2026 after acquiring DCJet and expanding its technician network.

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MRO (Maintenance, Repair, and Overhaul) provider West Star Aviation achieved a record 84% acceptance rate for Aircraft on Ground (AOG) requests in May 2026, following a strategic expansion of its technician workforce.

In a press release issued on June 5, 2026, the company attributed the capacity increase to its March 3, 2026, acquisition of DCJet. The integration expanded West Star Aviation’s dedicated AOG network to over 250 technicians, up from 200, positioning the firm to handle higher volumes of unscheduled maintenance events ahead of the summer travel season.

DCJet acquisition drives network expansion

The March acquisition of DCJet added five new locations to West Star Aviation’s nationwide footprint: Dulles International Airport (IAD), Chicago Midway International Airport (MDW), Orlando International Airport (MCO), Boeing Field (BFI), and Luis Muñoz Marín International Airport (SJU).

The expanded workforce is supported by a 24/7/365 AOG control center staffed by 12 controllers. This centralized coordination allows the MRO provider to dispatch technicians, tooling, and ground support equipment across its network to minimize operator downtime.

Gary Lee, Vice President of AOG at West Star Aviation, stated that the added resources are essential for meeting customer needs during critical periods of high demand.

“With access to tooling and GSE across our network, we’re poised to respond quickly, safely, and effectively wherever our customers need us,” Lee said in the release.

Infrastructure growth and satellite facilities

The AOG capacity improvements coincide with broader infrastructure investments by the company, which employs over 3,000 professionals and has 79 years of industry experience.

On June 2, 2026, West Star Aviation announced the opening of its fifth satellite location at Addison Airport in Texas. The new 40,000-square-foot hangar provides scheduled and unscheduled maintenance, AOG support, and avionics upgrades specifically targeting the Dallas metroplex.

Stephen Maiden, CEO of West Star Aviation, noted that the DCJet integration strengthens the company’s ability to support business aviation operators with faster response times, greater coordination, and increased technical depth in the field.

AirPro News analysis

The business aviation sector relies heavily on rapid AOG response to maintain dispatch reliability, particularly during peak travel months. By acquiring an established AOG provider like DCJet rather than attempting to scale organically, West Star Aviation has immediately secured both trained personnel and strategic airport access. The reported 84% acceptance rate in May 2026 indicates that the integration is already yielding operational dividends. We expect MRO consolidation to continue as larger providers seek to capture regional market share and alleviate industry-wide technician shortages through strategic acquisitions.

Sources: West Star Aviation

Photo Credit: West Star Aviation

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MRO & Manufacturing

Airbus A350F Manufacturing Network Spans Five Countries

Airbus details the A350F freighter supply chain across the UK, Spain, France, Germany, and the US, with final assembly in Toulouse.

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Airbus has outlined the distributed global manufacturing footprint for its new A350F freighter, detailing a supply chain that spans five nations and culminates at the Final Assembly Line in Toulouse, France.

In a press release issued on July 23, 2026, the European aerospace manufacturer provided a comprehensive overview of the production process for the large widebody cargo aircraft. Based on the Airbus A350-1000 airframe, the A350F is designed to carry a maximum payload of 111 tonnes over a range of 8,700 kilometres. The manufacturer states the aircraft will provide a minimum 20 percent reduction in fuel consumption and carbon emissions compared to current in-service freighters. Airbus is currently manufacturing two A350F aircraft for a flight testing campaign scheduled to run through 2027.

European and transatlantic production network

The Manufacturing strategy for the A350F relies on specialized facilities across the United Kingdom, Spain, France, Germany, and the United States. In the United Kingdom, facilities in Filton and Broughton are responsible for engineering and manufacturing the carbon-fibre wingset and the equipped gear beam. Airbus completed the first A350F wingset in Broughton on June 2, 2025. French facilities handle the engine pylons in Saint-Eloi, complex aerostructures across Saint-Nazaire, Rochefort, Nantes, and Méaulte, and fully equipped front and centre fuselages in Montoir-de-Bretagne.

German operations produce the forward and aft fuselage sections across Stade, Augsburg, and Nordenham before assembly in Hamburg. Germany is also responsible for the vertical tail plane, upper wing covers, and the surround structure and actuation system for the main deck cargo door. In the United States, component panels are manufactured at specialist facilities that Airbus integrated from Spirit AeroSystems in 2025. Components from all locations are transported to the Final Assembly Line (FAL) in Toulouse by air, land, and sea, heavily utilizing the Airbus BelugaXL air transporter.

Spanish facilities deliver critical composite structures

Spain plays a central role in the A350F program, contributing the rear fuselage, horizontal stabiliser, lower wing cover, belly fairing, and the main deck cargo door. Airbus completed the first horizontal stabiliser for the freighter in Spain on July 23, 2025.

A major engineering focus has been the main deck cargo door, which features a clear opening width of 4.3 metres and a height of 3.15 metres. Airbus completed the manufacturing and assembly of the first door in Illescas, Spain, on April 23, 2026, before delivering it to the Toulouse FAL for integration into the first test aircraft. Ricardo Rojas, President of Airbus Commercial Aircraft in Spain, described the Delivery as “the result of years of preparation and extensive teamwork,” highlighting the Illescas plant’s decades of expertise in composite materials. Testing of the cargo loading and main deck door actuation systems began on May 11, 2026.

AirPro News analysis

The detailed breakdown of the A350F manufacturing footprint highlights the immense logistical coordination required to bring a new widebody freighter to market. By distributing the production of massive composite structures across specialized European and American facilities, Airbus is leveraging its existing A350-1000 industrial base while integrating new capabilities specific to the Cargo-Aircraft market. We view the successful delivery of the massive 4.3-metre-wide main deck cargo door as a critical de-risking milestone for the program. The integration of former Spirit AeroSystems facilities into the direct Airbus supply chain also demonstrates a strategic consolidation of critical aerostructure manufacturing as the company prepares for the A350F flight test campaign.

Sources: Airbus

Photo Credit: Airbus

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MRO & Manufacturing

NPAS Orders Two More Airbus H135s, Fleet Renewal Reaches Nine

UK National Police Air Service expands its Airbus H135 order to nine helicopters under a six-year exclusive supply contract.

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The United Kingdom’s National Police Air Service (NPAS) has expanded its fleet renewal program with a firm order for two additional Airbus H135 helicopters, bringing the total number of new H135s on order to nine.

Announced in a press release on July 20, 2026, at the Farnborough International Airshow, the agreement builds on a 2025 Framework Contract negotiated alongside BlueLight Commercial. That contract established Airbus as the exclusive helicopter supplier for NPAS for a period of up to six years. The two newly ordered rotorcraft are scheduled to arrive at Airbus Helicopters’ Oxford facility for police-specific configuration in 2028.

Modernizing the UK police aviation fleet

NPAS currently operates a mixed fleet comprising 16 Airbus H135 and four Airbus H145 helicopters. These aircraft operate from 14 locations to support 43 police forces across England and Wales. The fleet renewal program aims to replace older airframes and standardize the technology available to airborne law enforcement crews.

The first two Airbus H135 helicopters from the initial renewal order arrived at the Airbus Helicopters facility in the UK in April 2026 to begin their policing customization process.

“These aircraft will provide a modern, resilient and effective capability for policing, supporting our crews as they respond to incidents, assist officers on the ground and protect the public,” said Chief Superintendent Fiona Gaffney, Accountable Manager for NPAS. “Together with our partners, we are building a fleet that will serve policing and the public for many years to come, ensuring NPAS remains ready to meet the evolving demands of operational policing.”

Avionics upgrades and Farnborough context

The incoming H135 helicopters will be equipped with the Airbus Helionix avionics system. To prepare for the transition, NPAS pilots have already commenced familiarization flights and training on the new suite. The Helionix system is designed to reduce pilot workload and improve situational awareness during complex law enforcement operations.

Richard Atack, Managing Director of Airbus Helicopters in the UK, stated that the company’s Oxford facility will utilize its design and customization expertise to equip the fleet with the latest security and policing technology.

The NPAS order was one of several rotorcraft agreements announced by Airbus on the opening day of the Farnborough International Airshow. The manufacturer also secured an order for eight Airbus H145 helicopters from Saudi Arabia’s The Helicopter Company (THC).

AirPro News analysis

The decision by NPAS to exercise options for additional H135s underscores the operational value of fleet commonality. By committing to a single manufacturer through the 2025 Framework Contract, NPAS simplifies its maintenance, repair, and overhaul (MRO) requirements while streamlining pilot training. The transition to the Helionix avionics suite across the new airframes will likely yield long-term safety and efficiency benefits for crews operating in high-workload urban environments. We view this incremental order as a strong indicator that the initial customization and integration phases of the fleet renewal program are proceeding according to schedule.

Sources: Airbus

Photo Credit: Airbus

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MRO & Manufacturing

FDH Aero and Gardner Aerospace Sign Five-Year Airbus Supply Deal

FDH Aero and Gardner Aerospace announce a five-year global supply partnership covering Airbus programs across five countries.

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FDH Aero and Gardner Aerospace announced a five-year global supply partnership on July 23, 2026, to support all Airbus commercial single-aisle and twin-aisle aircraft programs. The agreement expands an existing relationship to provide direct line feed, kitting, and C-class commodity management services across five countries.

In a press release issued by FDH Aero, the supply chain solutions provider confirmed the long-term agreement will support Gardner Aerospace facilities in the United Kingdom, France, Poland, India, and China. The partnership aims to streamline manufacturing operations, support production ramp-ups, and minimize overproduction and excess inventory for Airbus platforms, including the Airbus A320neo, Airbus A330neo, and Airbus A350.

Expanding the European and Asian supply chain

The new contract builds upon a previous expansion signed on June 18, 2025. That earlier agreement facilitated the phased transfer of commercial aircraft programs to a new Gardner Aerospace manufacturing facility in Bengaluru, India. To support the regional growth tied to Airbus frame and wing parts production, FDH Aero established a dedicated Bengaluru office for its electronics and hardware divisions.

The July 2026 agreement broadens this scope globally. Ray Venables, Head of Sourcing at Gardner Aerospace, stated the partnership reinforces the company’s commitment to building a resilient supply chain.

“By enhancing our direct line feed and C-class commodity management across Europe and Asia, we’re improving efficiency, increasing supply resilience, and ensuring we continue to support our Airbus programs with the agility and precision our customers expect,” Venables said.

Operational integration and commodity management

Under the five-year agreement, FDH Aero will integrate its supply chain services directly into Gardner Aerospace production lines. The focus on C-class commodities, which typically include fasteners, bearings, and standard hardware, is designed to ensure uninterrupted availability of high-volume components required for Airbus assembly.

Fred Short, Chief Growth Officer of FDH Hardware, noted the company is focused on delivering the reliability required to support Airbus commercial programs across multiple international borders.

“By implementing robust value-added services across their international sites, we are committed to delivering the reliability and efficiency required to seamlessly support their Airbus commercial programs,” Short said.

AirPro News analysis

We view this five-year agreement as a direct response to the ongoing supply chain pressures facing major aerospace manufacturers. As Airbus pushes to increase production rates across its A320neo and widebody families, Tier 1 suppliers like Gardner Aerospace require highly synchronized logistics to prevent bottlenecks. By locking in a long-term commodity management contract with FDH Aero, Gardner is positioning itself to absorb Airbus production ramp-ups without carrying the financial burden of excess inventory. The geographic spread of this agreement also highlights the industry’s continued reliance on a distributed, multinational manufacturing footprint to meet original equipment manufacturer targets.

Sources: FDH Aero (July 2026 Press Release)

Photo Credit: FDH Aero

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