Q4 2024

Also Inside:
P2F

DENT
UPS AND DOWNS OF THE
CONVERSIONS MARKET

REG UPDATE

CHECKING
AC 43-9D

INDUSTRY LEADER
PROFILES
SPECIAL ADVERTISING SECTION
Innovative Solutions Abound FEATURING LEADING MRO COMPANIES
CFM MRO turns more than just wrenches. cfmaeroengines.com
It also turns heads in the boardroom. Our open, competitive MRO ecosystem is unique in
the industry because it gives you choice. You decide where to overhaul your LEAP engines,
meaning competitive pricing and more flexibility. Another reason to say LEAP. By example.

AREN’T BORN.

ENGINEERED.
LEADERS

THEY’RE
An open, competitive
MRO ecosystem.
 Q4 2024

Also Inside:
P2F

DENT
UPS AND DOWNS OF THE
CONVERSIONS MARKET

REG UPDATE

CHECKING
AC 43-9D

INDUSTRY LEADER
PROFILES
SPECIAL ADVERTISING SECTION
Innovative Solutions Abound FEATURING LEADING MRO COMPANIES
Complex
MRO vendor
network?
We are your one
stop shop for repair
excellence

AJW Group is the world-leading, independent, parts, repair, lease, engine,

flight hour programme and supply chain solution integrator, transforming
efficiency in commercial, business and defence aviation.

With hubs and offices on every continent - including AJW Technique,

a state-of-the-art component MRO facility in Montreal
- nose to tail, we have you covered. ajw-group.com
SUBSCRIBE for free via www.avm-mag.com/subscribe

Q4 2024

The World’s Leading Aviation MRO Publication

DEPARTMENTS
04 Editor's Notebook issue, Frank Balonis continues
+44 (0)20 3892 3050
with more thoughts on +1 (920) 214 0140
06 Intel securing defense information
EDITORIAL
and CMMC 2.0's impact on Editor-in-Chief
56 Guest Column: In a follow-up cybersecurity requirements. Joy Finnegan
[email protected]
to his advice in the spring Contributing Editors
Q4 2024
James Careless Mazzy Beasley
Mark Robins Ian Harbison
Jason Dickstein Dale Smith
Jeff Guzzetti James T. McKenna
COVER STORY
ADVERTISING/ BUSINESS
Innovations in Dent Checking

42
Publisher/Owner
Adrian Broadbent
Aircraft dents happen. Some dents may have [email protected]
minimal effects, others can compromise an U.S. Sales Director
aircraft’s structural integrity and aerodynamic Greg Szatko
performance, making dent checking crucial. [email protected]
Also Inside:

Cover image courtesy of 8tree P2F

DENT U.S./Canada Sales Director

UPS AND DOWNS OF THE
CONVERSIONS MARKET

REG UPDATE
Daniel Goodwin
CHECKING
AC 43-9D

INDUSTRY LEADER

Innovative Solutions Abound

PROFILES
SPECIAL ADVERTISING SECTION
FEATURING LEADING MRO COMPANIES
[email protected]

16 P2F Update International Sales Director

Kyra Willis
[email protected]
The P2F market is experiencing an uncertain period but, overall, things
are looking good.
DESIGN/PRODUCTION

21
CPUK Print Publishing
Industry Leader Profiles www.cp-uk.co.uk
Our special advertising section called "Industry Leader Profiles' is
CLIENT SERVICES
back, where companies can tout their expertise in whatever area of the Administration
business they are in. Maria Hernanz Reyes
[email protected]

38 Changes Coming to AC No. 43-9D

A major update to aircraft records AC No. 43-9D may be coming soon.
PRINTER
CPUK Print Publishing
Richard Scarborough takes a look and boils the information down to www.cp-uk.co.uk

what you should know about these proposed changes. MAILING

Spatial Global Limited

46 A Conversation with RH Aero's Dieter Moeller

and Anthony Turner
Derby, UK

Rhinestahl acquired HYDRO Aero and the two companies merged

to form RH Aero. Joy Finnegan spoke to Anthony Turner, the new
president and CEO, and Dieter Moeller, chairman, to learn about the
integration of the two companies and what’s to come.

48 Maintenance Training Update

CAE's Shaun Kuldip, global leader of CAE’s Maintenance Training CoE,
talks about the trends driving MRO technical training.

50 Tools of the Trade

Tools can make the life of a maintainer easier and more efficient, or
drive them crazy if they are poorly designed or made. We take a look
at a few of the latest and greatest.
The World’s Leading Aviation MRO Magazine

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 E D I T O R ’ S C O M M E N T

The Dawn of the Digitization of Aviation Maintenance

BY JOY FINNEGAN
EDITOR-IN-CHIEF

A
s we enter the holiday season and speed toward the new thorough by accessing hard-to-reach parts of the aircraft. You can
year, 2025, I wanted to take a moment to recap some read about one use case for drones in our story on dent checking,
interesting developments in the aviation maintenance starting on page 42.
business this past year. Perhaps you have seen or read about the integration of
After the pandemic, air travel rebounded fast. Pent-up demand augmented and virtual reality (AR/VR) in our niche market. These
to travel whether to see family, to see clients for business or simply tools promise to enhance training, repair accuracy and reduce
to explore the world and have fun, was enormous. It has shown no reliance on manual inspections, which will eventually — hopefully
signs of slowing down yet either, and perhaps even continued growth. — lead to increased safety and speed of service. The promise is
MRO spending is projected to reach record levels, and managing there and now we need to see how it will play out.
costs and operations efficiently is more challenging than ever. What about AI — artificial intelligence? Will that be integrated
At the same time, even before 2020, inklings of a true shortage even more deeply into the daily lives of maintainers, planners and
of aircraft mechanics in the workforce was becoming reality. A related areas like operations? After all, it is a key component of
large portion of certified A&P mechanics is retiring or nearing predictive maintenance, the use of which is going to be crucial
retirement, intensifying the need for recruitment and upskilling going forward. Other nuanced areas where AI will be key are
of new talent. The confluence of these happenings made the condition monitoring, fault diagnosis and data analytics. Yes, there
mechanic shortage clear and top of mind for all. are legitimate concerns about the implications of AI use in aviation
Redoubled efforts by everyone in aircraft maintenance to maintenance. But proactive measures can and must be taken
reach out to youth and try to entice them into the industry started to mitigate risks and maximize the benefits of AI technology to
happening. High school and community college outreach to funnel ensure safe and efficient aircraft operations.
kids into the technical trades is happening and many are doing Every maintenance operation is concerned with compliance.
a great job of it. But it takes a long time to fill that pipeline and Modern digital solutions must come with the ability to meet
see the fruits of that labor turn into truly qualified, experienced regulatory requirements more efficiently. Robust security features
workers in the form of A&P mechanics on the hangar floor. will also be key. These can help companies protect sensitive data
Retention and attrition are issues. Wages in the industry need and avoid legal issues.
to rise to meet this demand and the sector struggles to retain The convergence of technology adoption and labor strategies is
qualified technicians due to competition from other industries and critical for the future competitiveness and continued safety of the
the complexity of modern aircraft systems. aviation industry. Embracing these changes offers opportunities
Aircraft increasingly rely on sophisticated electronics, for innovation but requires strategic investments in workforce
emphasizing the demand for technicians skilled in avionics and development and technological integration.
software, along with more traditional mechanical expertise. These Some say technological adoption remains slower in the
skills gaps are challenging the industry as well and will continue maintenance sector than other areas of aviation due to regulatory
to do so for years to come as retirements increase and new, and business challenges. But investment is clearly on the rise as
inexperienced workers enter the workforce. companies seek to streamline operations through digital tools and
These truths have spurred shifts in the aircraft maintenance process innovations.
industry, and it has begun to look to technological innovations Embracing technology also comes with challenges such as costs,
as they can assist in these evolving workforce dynamics like cybersecurity risks and potential resistance to change. Companies
never before. must carefully plan and manage their digital transformation efforts
Technological advancements are helping the aircraft to ensure they align with their overall strategy and receive buy-in
maintenance industry in multiple ways, but most importantly as from employees. But our industry must embrace it.
force multipliers. Programs for predictive maintenance, driven by Those that embrace technology and digitization will gain the
huge fonts of data, are helping enable operators to anticipate competitive advantage by becoming more efficient, utilizing data-
and address maintenance needs, improving cost efficiency and driven decision-making and becoming more agile, all of which will
reducing aircraft downtime. lead to better customer experiences. Better customer experiences
One cool development that is being embraced these days is will lead to repeat customers and continued full hangars.
the use of drones in the hangar. Drone technology is increasingly The dawn of the digitization of aviation maintenance is upon us.
used for inspections, making maintenance quicker, safer and more

4 Aviation Maintenance | avm-mag.com | Quarter Four 2024

MOBILIZING
MAINTENANCE
Real-time maintenance information,
anytime, anywhere

[email protected] | www.emro.com
AFI KLM E&M Announces Leadership Transitions

Air France Industries KLM Engineering & Maintenance (AFI KLM

E&M) announces significant leadership changes: Ton Dortmans,
executive vice president of KLM Engineering & Maintenance
(KLM E&M), will retire in summer 2025, after an impressive
40-year career with KLM Royal Dutch Airlines. Mathieu Essenberg,
currently serving as EVP Hub Operations in charge of Ground
Services, will succeed him on January 1, 2025.
Ton Dortmans joined KLM on August 1, 1985, and held
various positions within E&M before transitioning to Ground Ton Dortmans Mathieu Essenberg
Services, where he was responsible for redesigning ground
handling processes. From 1998 to 2008, Ton held multiple roles of Ton Dortmans, executive vice president of KLM E&M,
within Flight Operations, including responsibilities for Air Traffic effective summer 2025. Ton's remarkable 40-year career with
Management, deputy EVP Flight Operations and serving as SVP KLM Royal Dutch Airlines has been marked by unwavering
Operations Control Center in the Passenger division from 2005. dedication, exceptional leadership, and a profound impact on
He returned to E&M in December 2008 as SVP Operations and our organization. As we welcome Mathieu Essenberg, who will
Deputy EVP, eventually becoming EVP of KLM E&M in February succeed him, we are confident that Mathieu’s expertise and
2012, joining also the Executive Teams of KLM and Air France innovative approach will continue to drive our mission forward. We
Industries KLM E&M. extend our heartfelt thanks to Ton for his precious contributions to
In addition to his role within KLM E&M, Dortmans has KLM E&M and AFI KLM E&M.”
represented KLM in several capacities, including chairman of Mathieu Essenberg will start his new role on January 1, 2025.
EPCOR B.V. and board member of KLM UK Engineering. He has Dortmans will support Essenberg for smooth handover of all
also participated in various committees with Schiphol Group, Air activities. In close cooperation with Anne Brachet, Dortmans will
Traffic Control the Netherlands, and the government, such as the manage significant major projects for AFI KLM E&M, among other
Regional Consultation Schiphol (CROS). collaborations with OEMs and Supply Chain projects.
“As EVP of KLM E&M, you are responsible for one of the Essenberg has been with KLM since 2002 and has held various
largest technical enterprises in our industry, tasked with timely management roles at KLM Cityhopper and Flight Operations. At
and safely maintaining and repairing KLM's aircraft, engines, and KLM E&M, he served as SVP Airframe/Operations, overseeing
components, as well as those of around 200 global customers,” aircraft maintenance for KLM’s fleet and global customers.
said Marjan Rintel, CEO of KLM Royal Dutch Airlines. “Ton has Additionally, Essenberg has 20 years of experience as a pilot with
fulfilled this immense responsibility with great dedication, a KLM and KLM Cityhopper, serving as captain on Boeing 737.
passion for technology, and a deep care for the people behind In 2022, he became EVP Hub Operations, leading the Ground
it. He has successfully steered E&M through challenging times, Services division.
including significant downsizing during covid and subsequent Marjan Rintel added, "The maintenance and thus the availability
scaling up and recruitment efforts. I sincerely thank Ton for his of our fleet is our top priority. Mathieu has proven that he can
invaluable contributions to KLM and wish him all the best in his lead significant changes while also addressing daily challenges. His
well-deserved retirement.” strategic vision and pragmatic results-oriented approach make him
Anne Brachet, EVP Air France-KLM Engineering & Maintenance, the right person to lead E&M."
stated, “With immense gratitude, we announce the retirement

Lufthansa Technik Approves Billion-Euro Investments

Lufthansa Technik 2030 corporate strategy, Lufthansa Technik had announced its
continues on its intention to increase its commitment not only in North America,
course of growth and but also in Asia.
has decided to invest “To finance our growth and investments, we must, of course,
well over one billion also generate corresponding revenues,” says Willms. Lufthansa
euros in the coming Technik continues to target an Adjusted EBIT for the 2024
years. Investments financial year at a level comparable to the record result of
will be made in all the previous year (628 million euros), despite the significant
three world regions, challenges facing the aviation industry, such as ongoing difficulties
i.e., the Americas, in the supply of materials. After the third quarter, the figure is
Asia-Pacific already valued at 486 million euros (+5.9 percent compared to the
(APAC) and Europe, Middle East and Africa (EMEA). “Our plans same period last year).
substantiate our aim to expand our leading market position,” said The company’s revenue increased by as much as 13.9 percent
chief financial officer, Dr. William Willms. As part of its Ambition to 5.5 billion euros in the first nine months of the year and is

6 Aviation Maintenance | avm-mag.com | Quarter Four 2024

expected to exceed the seven billion euro mark for the first workshop at the Hamburg location was celebrated a few weeks
time at the end of the year. Lufthansa Technik continues to ago. The construction of two more large workshop buildings at the
successfully secure its future business and has already signed 523 company's headquarters has become definite. The investment by
new contracts this year (previous year period: 587). In addition to Lufthansa Technik in Hamburg alone is in the mid three-digit million
reaching agreements in the company's traditional core segments euro range. However, money will not only be used to expand
of engine and component services, innovations in the areas of and modernize existing sites, but also for new ones. It will soon
digitization and sustainability are also paying off. be known where Lufthansa Technik will build a new plant for the
With LATAM from South America, ANA as well as EVA Air overhaul of engine parts and aircraft components in southwestern
(both from Asia), Lufthansa Technik says it has, for the first time, Europe. Plans for two other major investments outside Europe are
equipped airlines outside the Lufthansa Group with AeroSHARK also well advanced and will be announced shortly.
in recent months. The functional surface film developed together To achieve its ambitious corporate goals, Lufthansa Technik
with BASF successfully imitates the skin of sharks, reduces the is also focusing on inorganic growth. The acquisition of an 80
aerodynamic drag, and enables significant fuel savings. With its percent stake in ETP Thermal Dynamics of Tulsa, Oklahoma, in
Digital Tech Ops Ecosystem, Lufthansa Technik continues to score the U.S. this autumn, for example, represents a targeted portfolio
highly with customers in the digital arena. Since its introduction expansion in the components business. ETP specializes in aircraft
in 2023, its modules have already added value in the servicing of heat exchangers as well as oil and fuel coolers. The company said
thousands of aircraft. A special cabin modification agreement was the acquisition not only strengthened capacities in this area but also
also announced in the third quarter. As the first Boeing-licensed its supply chain. In addition, significant investments continue to be
service center, Lufthansa Technik will modify the cabin interiors on made in materials and personnel. At the end of September, 24,114
787 Dreamliner aircraft. people were working for Lufthansa Technik worldwide, an increase
The ceremony to mark the topping out of a new hydraulics of about 2,000 employees compared to the same time last year.

Aero Norway Appoints Kenneth Johnston to LEAP Program Manager

Aero Norway has appointed Successfully navigating the introduction of LEAP services
Kenneth Johnston as LEAP will position Aero Norway as a leader in the advanced engine
program manager to help MRO sector, supporting its customers with the growing demand
with the integration of new for these services in the global aviation market. Many airlines
capabilities. He will be and operators who are currently operating CFM56 engines are
responsible for promoting Aero transitioning to the LEAP models, especially on new aircraft such
Norway's LEAP capabilities as the 737MAX and A320 neo.
and implementing the The facility will be handling both CFM56 and LEAP engines,
organization’s readiness plan without increasing the shop footprint. The design allows for flexibility,
for LEAP repairs. enabling it to adapt to the varying demands of servicing these two
Johnston explains what attracted him to the role: “The LEAP different engine types and this hybrid approach will be the most
engine is one of the most advanced and widely used aircraft effective for Aero Norway’s customers that operate both types.
engines in the industry, powering popular aircraft like the Boeing As the industry moves towards more sustainable practices, Aero
737 MAX and the Airbus A320neo. By offering services for Norway’s expertise in engine MRO will be essential in adapting
the LEAP engine, Aero Norway reinforces itself as a key player to new engine technologies and ensuring they operate efficiently
in the maintenance, repair and overhaul (MRO) market for throughout their lifespan. This alignment of maintenance excellence
modern, high-demand aircraft. Handling LEAP engines requires with environmental goals is crucial for the aviation industry to
advanced technological capabilities and expertise. By successfully meet the demands of a growing traveling population while also
incorporating LEAP into our portfolio, Aero Norway demonstrates addressing the urgent need to reduce carbon emissions.
our ability to work with cutting-edge technology, enhancing our Johnston goes on to say that the future of aircraft engines
reputation as a highly skilled and reliable MRO provider. is poised for significant advancements. “The industry is
“Overall, having LEAP in our portfolio significantly enhances Aero increasingly focused on developing and implementing greener
Norway's competitive positioning, opens new revenue streams, and technologies, such as more efficient engine designs, alternative
aligns the company with the future of aviation technology.” Aero fuels, and hybrid-electric propulsion systems. In this context,
Norway is poised to make a significant investment in specialized MRO organizations like Aero Norway play a critical role. By
equipment and has undergone a comprehensive process to obtain extending the life and improving the efficiency of existing engines
approvals to offer LEAP MRO services. This process involved close through precise maintenance and innovative repair techniques,
collaboration with the OEM, extensive training and certification MROs contribute to lowering overall emissions. For instance,
of personnel, facility upgrades, and rigorous regulatory oversight. regular maintenance ensures engines operate at peak efficiency,
LEAP engines typically require a team of dedicated specialists due consuming less fuel and emitting fewer pollutants. Additionally,
to their advanced technology and Aero Norway’s approach ensures by refurbishing and upgrading engines with the latest eco-friendly
that tasks are carried out efficiently, safely, and in compliance with technologies, Aero Norway can help airlines reduce their carbon
all regulatory requirements. footprint without needing to replace entire fleets.”

Read the latest issue online via avm-mag.com/current or avm-mag.com/back-copies Aviation Maintenance | avm-mag.com | Quarter Four 2024 7
ABB Drive Modernization Gives NASA’s Wind Tunnel a New Lease on Life

cryogenic temperatures. As a result, the NTF can simulate a wider

range of flying conditions than any other wind tunnel, enabling
engineers to gain unique insight and hone aircraft designs.
After ABB’s service specialists evaluated the performance and
mechanical connections of the existing drive, the next step was
to develop a solution based on modern high-efficiency power
electronic components to match the original drive’s maximum
power, while achieving high availability and reliability. This resulted
in the modernization of the drive, to replace key components
inside the existing footprint with the latest ABB state-of-art
technology. The scope included upgrading the small part of the
drive (control unit), which minimized the duration and disruption
of the project and demonstrated circularity by minimizing waste
and logistics as much as possible.
“NASA relied on ABB’s domain expertise, technology and
As part of an ABB Motion OneCare service agreement, ABB has services to ensure its National Transonic Facility (NTF) provides
modernized a variable speed drive (VSD) for NASA (U.S. National high reliability and uptime to maximize availability for its testing
Aeronautics and Space Administration) to extend, by at least 10 programs — and optimize the life-cycle value of its assets,” said
years, the life of the wind tunnel at its National Transonic Facility Oswald Deuchar, head of modernization services, ABB Motion.
(NTF) at Langley Research Center in Hampton, Virginia. The tunnel “Extending the life of the wind tunnel by at least 10 years
is used to optimize aircraft performance and fuel consumption supports NASA’s operational goals, while upgrading the drive’s
by mimicking flight conditions at high altitudes and close to the key components demonstrates efficiency and circular approach.”
speed of sound. It has been used to test the Boeing 777, the NASA ordered the upgrade project as the first activity under an
Space Shuttle and its Booster Rocket. ABB Motion OneCare service agreement that also covers spare
In 2021, NASA’s engineers identified a need to upgrade the parts and maintenance. This type of agreement provides the
tunnel’s medium voltage (MV) drive, due to the aging of the drive’s flexibility for operators like NASA to bundle together the services
components. ABB supplied the drive in 1997 as the most powerful of they want so that they can optimize the life cycle of their motors,
its kind in the world: the 101-megawatt (MW) drive can test models generators and drives.
in air or nitrogen flowing at transonic speeds and at ambient or

ExecuJet Haite Completes Three 96-Month Inspections Simultaneously on Embraer Legacy Aircraft

ExecuJet Haite’s maintenance center at Tianjin’s Binhai

International Airport in China has completed 96-month
checks on three Embraer Legacy 650 aircraft.
The work on all three Embraer aircraft was
performed simultaneously and within four months.
One of the aircraft completed its heavy maintenance
check in nine weeks. The 96-month inspection is the
most extensive on the Legacy airframe and entails
over 3,000 labor-hours. This heavy check includes full
removal of the cabin interior, down to the fuselage
frames for structural inspection. Both the forward and
ventral fuel tanks are also removed, as is the wing
leading edges, flaps, landing gear and flight controls.
“Completing these highly complex projects
in less than four months, further demonstrates
our proficiency in managing and simultaneously
performing multiple heavy base maintenance
inspections while still ensuring that we keep within
our customers’ demanding flight schedules and
budgets,” says Paul Desgrosseilliers, general manager
of ExecuJet Haite. “We will continue to strengthen
our processes and procedures to improve our overall
quality and minimize aircraft downtime.”

8 Aviation Maintenance | avm-mag.com | Quarter Four 2024

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AJW Group Appoints Mitsui as Sole Sales Representative in Japan

AJW Group, independent provider of aircraft component parts, capitalize on Japan’s aviation industry’s growth.”
repair and supply chain solutions to the commercial, business Nick Ward, SVP global sales and BD of AJW Group, said, “Our
and defense aviation sectors, is further strengthening its partnership with Mitsui expands our ability to enhance our aircraft
presence in Japan with the appointment of Mitsui & Co. as its components and supply chain solutions to serve this key market
sole sales representative. and provides enhanced MRO support for our Japanese customers,
This strategic partnership enhances AJW Group’s capacity to utilizing AJW Technique’s extensive capabilities.”
support the Japanese market, enabling the supply and support of
aircraft components through contracted services such as Power-by-
the-Hour (PBH), as well as providing full maintenance, repair and
overhaul (MRO) capabilities for aircraft components within the region.
Aligned with AJW Group’s global growth strategy, this
collaboration will bolster the Group’s footprint in Japan’s aviation
industry. AJW Technique, the Group’s world-class MRO facility
based in Montreal, was the first independent component MRO in
the world to receive Japan Civil Aviation Bureau (JCAB) approval
under the Bilateral Aviation Safety Agreement (BASA) with
Transport Canada (TCCA), a milestone achieved in January 2019.
This recognition underscores AJW Technique’s compliance with
JCAB regulations and positions the Group as a trusted partner in
the Japanese MRO market.
“This partnership comes at a pivotal time for Japan’s aviation
market,” said Tetsuro Hidaka, GM new business development,
aerospace business, Mitsui. “Our collaboration with AJW, a
recognized global leader in aircraft components, will enable us to Nick Ward

Lufthansa Technik to Support Avianca's LEAP-1A Engines

Lufthansa Technik has entered into a non-exclusive contract with “We are excited to support Avianca in maintaining the high
Avianca, an air carrier in Latin America, to provide maintenance performance of their LEAP-1A engines."
support for CFM International LEAP-1A engines. This agreement In addition to this agreement, Avianca benefits from several
marks Avianca as Lufthansa Technik's first customer in South key services provided by Lufthansa Technik, including a
America to benefit from Lufthansa Technik's LEAP-1A services. comprehensive Total Component Support for its Boeing 787
Through this cooperation, Lufthansa Technik will provide fleet. Additionally, the airline has adopted AVIATAR's Condition
quick turn services for the LEAP-1A engines powering Avianca's Monitoring and Predictive Health Analytics to enhance its
A320neo fleet. These services are designed to address specific maintenance processes. In early 2024, Avianca completed
technical issues swiftly and cost-effectively, allowing engines to its migration to the AMOS cloud, further improving its fleet
return to service quickly without the need for a full overhaul. This management capabilities.
approach minimizes downtime and maximizes cost-efficiency,
allowing Avianca's fleet to remain in service longer.
"We are very pleased to announce a new agreement with
Lufthansa Technik, this time to support the maintenance of the
LEAP-1A engines of our A320neo fleet. This is a result of the
great teamwork we have achieved. We are very focused on
becoming more and more efficient and this agreement will allow
us to move forward on that path," said Francisco Lalinde, senior
vice president of engineering and maintenance at Avianca.
Lufthansa Technik was the first independent MRO provider
worldwide to conclude a service agreement for the two engine
types LEAP-1A and LEAP-1B, thus securing access to the fleets
of the future. In 2018 the company performed the very first full
performance restoration shop visit on a LEAP-1A worldwide.
"This agreement with Avianca, our first LEAP-1A quick turn
contract in South America, underscores our ability to deliver fast,
reliable and cost-effective maintenance solutions,” said Alejandra
Castellote, director of saless Latin America at Lufthansa Technik.

10 Aviation Maintenance | avm-mag.com | Quarter Four 2024

StandardAero Completes Correlation of San Antonio Test Cell for LEAP-1A, Now Offering
Performance Restoration Shop Visit (PRSV) Capability for LEAP-1A and LEAP-1B

StandardAero’s engine overhaul center in San Antonio, TX has GM commercial programs

completed correlation of its first test cell for the CFM International for StandardAero’s Engine
LEAP-1A turbofan engine, thereby achieving another milestone in Services – airlines and fleets
its introduction of LEAP-1A and LEAP-1B maintenance, repair and division. “We will be correlating
overhaul (MRO) capabilities. The San Antonio facility is now able a second test cell to support
to undertake LEAP-1A functional and performance engine testing the LEAP-1A and LEAP-1B in
for Airbus A320neo family customers. the near future, expanding our
This addition of engine test capabilities for the LEAP-1A comes capacity and providing operators with the assurance of capability
three months after StandardAero’s 810,000-square-foot facility in San redundancy. Our team of MRO service specialists here in San
Antonio achieved correlation of its initial test cell for the Boeing 737 Antonio are dedicated to supporting the engine MRO needs of
MAX’s LEAP-1B powerplant. The achievement paves the way for the Airbus A320neo and Boeing 737 MAX operators worldwide, in
introduction of LEAP-1A and LEAP-1B performance restoration shop support of the LEAP open MRO ecosystem.”
visit (PRSV) capability, with PRSVs now being accepted. In addition to establishing MRO capability for the LEAP-1A
StandardAero supports the LEAP-1A and LEAP-1B as a CFM and LEAP-1B at its San Antonio facility, StandardAero is also
‘Premier MRO’ provider, having signed the first North American industrializing new engine component repairs for the LEAP family
non-airline CFM Branded Service Agreement (CBSA) for the LEAP- through its Component Repair Services (CRS) division’s network of
1A and LEAP-1B in March 2023. The San Antonio facility initially locations, and its Repair Development Center of Excellence. To
began accepting LEAP Continued Time Engine Maintenance date, StandardAero’s CRS team has developed and industrialized
(CTEM) shop visits in March 2024. more than 250 component repairs for the LEAP-1A and LEAP-1B.
“StandardAero is pleased to introduce its new LEAP-1A test cell StandardAero also continues to grow its team of LEAP
capability in support of the global A320neo community, adding technicians through its in-house Aviation Mechanic Training
to our existing LEAP-1B capability,” said James Campbell, VP/ Program, located at its San Antonio site’s Training Academy.

CFM56® engine services

Independent MRO delivering globally recognised, flexible,
multi-release workscopes for CFM56® series engines.

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It’s precisely why operators choose Aero Norway.

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Eve Air Mobility Presents Eve TechCare

Eve Air Mobility announced the launch of its fully integrated Eve TechCare’s service and support solutions will cover all
aftermarket services portfolio for efficient and safe Urban Air Mobility the operational aspects necessary to ensure the daily eVTOL
(UAM) operations. Eve TechCare is an all-in-one suite of solutions operation. This includes access to a 24/7 customer care center,
designed to streamline electric vertical takeoff and landing aircraft pilot and mechanic training, entry into service support, technical
(eVTOL) operations by providing the industry with comprehensive and operational publications, material and battery services,
services, customer support and operational solutions. aircraft health monitoring, and MRO services. Eve will offer a
“At Eve, our focus goes beyond developing and producing an different support level approach to guarantee that each customer
eVTOL; we take a holistic approach to the market by creating a can benefit from its solutions according to their needs, ensuring
suite of solutions to address the necessary aspects that will turn efficiency and profitability.
urban air mobility into a reality. With Eve TechCare, we will ensure Eve has a large backlog with letters of intent for 2,900 eVTOL
the best operational aircraft availability for our customers while aircraft, representing a potential $14.5 billion in revenue across
optimizing operational costs,” said Johann Bordais, CEO of Eve. 30 customers in 13 countries. Beyond the aircraft, Eve secured
"Our goal is to offer our customers everything they need from the non-binding contracts with 14 of these customers for service
moment they receive their aircraft onward." and operations — with approximately 1,100 eVTOL aircraft —
Backed by Embraer’s 55 years of history and aerospace industry representing a potential revenue of $1.2 billion during the first five
expertise, Eve TechCare offers a unique way of serving customers years of operation.
with a global footprint and local presence. The aftermarket Eve says it has successfully assembled its first full-scale prototype
portfolio consists of technical support and solutions, MRO and completed the selection of primary suppliers for the aircraft. The
services, parts and battery solutions, as well as training services company is advancing the current stage of the eVTOL development,
and flight operation solutions, which operators will access through which involves a series of comprehensive tests with the prototype
a digital platform. aimed to evaluate every aspect of the aircraft’s operation and
"Our portfolio is designed for operational efficiency and safety performance, from flight capabilities to safety features.
with a unique customer-centric approach. We’ve developed
these solutions based on our aerospace expertise and diverse
interactions with customers and partners. The result is a first-of-
its-kind offer that will keep our customers’ eVTOLs flying at a high
availability rate,” added Luiz Mauad, vice-president of customer
services at Eve. “We are excited about this new phase in customer
services at Eve, which will allow us to discuss our service packages
with our customers further and recommend the best solutions for
their operation.”

APOC Aviation Secures Flexible Funding Facility With Deutsche Bank

APOC Aviation, the intuitive trading and leasing specialist focused expenditure on aircraft and engine assets in the next 12 months.”
on engines, landing gear and USM components, has secured a APOC’s majority shareholder is private equity investor Egeria.
significant multi-faceted financing facility with Deutsche Bank The Netherlands-based fund has worked closely with the company
AG via its transportation structured finance group. The funds since 2020. It continues to spearhead APOC’s transformative
will be used to expand APOC’s existing business portfolio whilst global footprint with a focus on continued vertical integration at
underpinning further vertical integration of future complementary the forefront of the industry’s sustained recovery. “As the majority
solutions. The flexibility offered by Deutsche Bank enables APOC shareholder, Egeria endorses the funding facility with Deutsche
to grow exponentially in both the short and medium term. Bank and is contributing additional equity into the business to
“APOC is pursuing a dynamic trajectory as the business fortify the continued growth program,” says Ivo Groen in ‘t Woud,
capitalizes on opportunities that have been identified for partner, Egeria.
expansion. We are pursuing a strategy of controlled growth that “We support APOC in its strategy to become a truly
will propel APOC into a different stratum for trading, stocking international USM (used serviceable material) provider and mature
and leasing aircraft assets,” said Gavin Simmonds, CEO. “We asset lessor. The business will become the intuitive choice for
will be very active in the market globally, so capital backing from leading airlines and it is our role to help APOC navigate a precise
an international major bank with an impeccable pedigree and and unwavering path to this outcome.”
reputation validates our plans. At the outset, we were focused Simmonds reiterates the importance of the Egeria relationship;
on securing a facility of appropriate size with diverse borrowing “Their commitment continues to safeguard the heart of APOC
criteria across a broad portfolio and aligned to our ambitious and — as an integral part of our team — Egeria stood by APOC
growth strategies. We have found Deutsche Bank’s open approach during the recent black swan event and are now working very
to be closely aligned to APOC’s company ethos and aspirations.” closely with us as we build upon our quality-centric asset trading
Simmonds added, “We will deploy US$140 million of capital portfolio which is already expanding exponentially. Having just

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past the considerable milestone of ten years’ trading, it is fitting that the facility and relationship will
that we should celebrate an evolution within our business model grow and evolve as APOC penetrates
that is fully supported by our investors and make a step-change a larger segment of the market with its
in both size and market offerings. The future is very exciting and I leasing, exchange, and general trading
know I speak for everyone involved when I say that APOC is more of major assets and LRUs. APOC have
than ready to embrace new challenges with energy, commitment demonstrated their market knowledge
and teamwork." within the chosen Airbus, Boeing,
Sneha Kedia from Deutsche Bank summarizes, “Deutsche Bank Embraer and ATR sectors and have an
is pleased to have partnered with APOC on a facility that expands aggressive expansion appetite which we
upon our more traditional aviation lending. We are confident are committed to funding as plans develop into tangible results.”

Revima and Asia Digital Engineering Join Forces With the Goal of Revolutionizing Fleet Management
With Predictive Maintenance Integration

Asia Digital Engineering (ADE) and Revima have formed a strategic maintenance for multiple aircraft systems seamlessly under a single
collaboration to enhance ADE’s digital fleet management platform, unified platform, significantly improving operational efficiency and
ELEVADE, through the integration of Revima’s advanced APU fleet oversight.
predictive maintenance solution, PREDICARE. A key phase of the partnership will involve integrating PREDICARE
Revima, a renowned independent specialist in Auxiliary Power Unit with ADE's primary airline customer, AirAsia, across a number of their
(APU) Maintenance, Repair and Overhaul (MRO), currently supports A320 fleet to ensure operational readiness. Following this trial phase, the
more than 250 aircraft globally with PREDICARE. This real-time solution will be rolled out to airline customers globally who utilize the
predictive maintenance and engineering support tool is focused on ELEVADE platform, further strengthening ADE’s digital service offerings.
providing proactive solutions to minimize downtime and improve "PREDICARE solution is a great complement to ELEVADE platform,”
fleet reliability. said Vikram Singh, director new services in REVIMA. “It enables us to
ELEVADE is an innovative all-in-one digital solution for the airline scale our reach while providing operators with an integrated, best-in-
and MRO industries, the first of its kind in Asia. This platform class predictive maintenance solution for different platforms.”
integrates essential functions, including fleet management, aircraft Adnan Mansur, head of digital and innovation services at ADE
health monitoring, and workforce optimization, enhancing aircraft said, "We are dedicated to driving innovation and delivering smarter,
maintenance and engineering management. Built on three pillars data-driven solutions to enhance fleet management. The integration
— fleet, people, and the upcoming feature material — ELEVADE of PREDICARE into ELEVADE marks a key milestone in realizing this
currently monitors over 200 aircraft and 3,000 personnel across vision. Through this collaboration, we are empowering airlines to
ASEAN, with three additional Asian airlines conducting trials to harness real-time insights and predictive capabilities for improved
experience its benefits. fleet reliability and reduced downtime. We are excited about the
The collaboration aims to integrate PREDICARE into ADE’s potential this partnership brings and look forward to offering a truly
ELEVADE platform, transforming it into a comprehensive, all-in-one unified platform for aircraft digital maintenance.”
solution for airlines. This will enable operators to manage predictive

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RH Aero Systems Unveils New Advanced Solution Landing Gear Equipment, MLGTMULTI-2, Designed
for Airbus and Boeing Widebody Aircraft

RH Aero Systems, a new company that emerged after Rhinestahl the traditional processes. Ground-based operation eliminates the
Corp.’s acquisition of HYDRO Systems in April, has officially need for cranes or on-wing work, significantly increasing safety
unveiled new landing gear equipment recently. during the process. Additionally, the system is optimized for
The MLGTMULTI-2 is an advanced solution specifically designed easy transport, enabling transport on standard pallets, without
to enhance the removal and installation operation of main landing requiring special handling or exceptional transport measures.
gears on common widebody aircrafts. It is designed for the “Our customers were very impressed with the MLGTMULTI-2 as
Airbus and Boeing widebody passenger and freighter fleets. it represents the newest generation in landing gear equipment,”
The landing gear change equipment is designed for a safer, said Martin Dürr, executive vice president. “We were delighted to
faster and more cost-effective operation. The system offers a officially unveil this innovative product to our customers and to all
range of advanced features designed for safety and efficiency, of the MRO Europe attendees.”
and it enables quick and secure trunnion disconnection thanks to The equipment was showcased at MRO Europe through a
its maneuverability and flexible design. The ergonomic hand-held digital twin of the MLGTMULTI-2. The demonstration provided
control panel (HMI) ensures user-friendly operation, while the customers with a hands-on experience of the MLGMULTI-2’s
MLGTMULTI-2 electrically controlled, high-precision movement capabilities, showcasing the company’s innovative approach to
provides significant advantages and ease of use compared to technology and the cutting-edge design of its solutions.

AAR Signs Engine Parts Supply Agreement With Chromalloy

agreement, AAR will be the exclusive distributor of

these two PMA blades to the global aftermarket
with limited account coverage exclusions, due to
Chromalloy’s pre-existing customer agreements.
“This agreement builds on the long relationship
between AAR and Chromalloy for connecting
innovative solutions to our global aftermarket
customers. The combination of the Chromalloy
engineering and manufacturing capability, with the
AAR global aero-engine channel access ensures that
our PMA solutions are accessible by operators and
repair stations in every region,” said Chris Celtruda,
Chromalloy’s chief executive officer.
“AAR is pleased to partner with Chromalloy and
to expand our aftermarket solution offerings to
include Chromalloy’s CF6-80C2 parts. AAR provides a
complete range of solutions for engine repair facilities,
ensuring access to the best value combination for
our customers,” said Sal Marino, AAR's senior vice
president of parts supply.
AAR Corp. announced the signing of a multi-year engine parts The agreement has an initial term of three years, and AAR has
supply agreement to distribute Chromalloy’s Parts Manufacturer made an initial provisioning order that ensures there is inventory
Approval (PMA) parts for the CF6-80C2 engine high pressure in place to provide for the global distribution of Chromalloy’s CF6-
turbine (HPT) Stage 1 and Stage 2 turbine blades. Under the 80C2 HPT Stage 1 and Stage 2 turbine blades.

TP Aerospace Extends Partnership With K-Mile Air

TP Aerospace has extended its partnership with Thai express cargo future fleet of B737CL and B737NG aircraft. The program is a fully
airline K-Mile Air with a new and updated long-term Wheels and integrated partnership between K-Mile and TP Aerospace, which
Brakes Program. will see TP Aerospace further strengthening and intensifying its
The continued partnership will see TP Aerospace supply K-Mile presence in Thailand and surrounding countries.
Air with its all-inclusive and plug and play wheels and brakes cost- “K-Mile’s renewed partnership is a true testament to TP
per-landing program, covering support of the airline’s current and Aerospace’s continued commitment to supporting both established

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 and new airlines in the exceptional, reliable support for our current and expanding fleet
region with its financial and reinforces our commitment to providing operational efficiency
and operational and reliable services for our customers,” said Pansith Sasunee,
beneficial full-service managing director of K-Mile Air. “With TP Aerospace’s growing
programs,” says TP presence in Asia Pacific, it is with genuine joy that we renew our
Aerospace global partnership with K-Mile Air. As our customers continue to grow
program director, Philip Broskov Hansen. bigger in their respective market, we grow alongside them with
In 2019, TP Aerospace opened an MRO facility in Thailand, from continued committed support,” says regional COO, APAC, Joe Tai,
where the signed CFR program will mainly be serviced. The MRO about the partnership.
facility is located only 10 minutes from Suvarnabhumi International K-Mile Air, operating as K-Mile Asia, is a specialist cargo operator
Airport, where the airline is based. serving the express freight industry from the airline’s base in
“K-Mile is delighted to extend our partnership with TP Aerospace Suvarnabhumi Airport, Bangkok. The Thai airline was established in
and continue to benefit from TP Aerospace’s comprehensive 2004 and began operations in 2006 providing both scheduled and
Wheels and Brakes Program. This continued collaboration ensures charter cargo flights.

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 By Ian Harbison

THE UPS AND DOWNS OF THE

P2F MARKET
THE FREIGHTER CONVERSION MARKET, ESPECIALLY FOR NARROWBODY
AIRCRAFT, IS IN A STATE OF POST-PANDEMIC DEPRESSION, MAINLY
CAUSED BY EXTERNAL PRESSURES. IAN HARBISON FOUND OUT MORE
FROM SOME LEADING PLAYERS.

A
ccording to the Airbus Global Market followed by five 737-400Ss, three CRJ200 SFs and two MD-80SFs.
Forecast 2024, the world freighter fleet in While the 737-800SF will again represent the majority of deliveries
service will reach 3,360 aircraft by 2043, up in 2024, he expects the total will be slightly below 2023 figures. The
from 2,220 in 2023, with the 2,240 deliveries company has stated that it will use this predicted slowdown as an
split between 1,140 for growth and 1,330 for opportunity to complete studies on potentially introducing new AEI
replacement, and 890 remaining in service. freighter programs for the 737-900 and the CRJ 900.
For the growth and replacement category, Deliveries this year include a 737-800SF freighter to Democratic
around 1,530 will be conversions. The deliveries are further split Republic of Congo-based Serve Air, with a further five to follow
into 970 single-aisle (10-40 tons), 880 mid-size widebody (40-80 in the coming years, and the twentieth CRJ200 SF freighter to
tons) and 620 large widebody (>80 tons). Saltillo, Mexico-based Aeronaves TSM, also the forty-second
The 2024-2043 Boeing Commercial Market Outlook does not overall freighter that TSM has ordered directly from AEI.
distinguish between new build and converted freighters but says Elsewhere, Grand China Aviation Maintenance (GCAM), a
the fleet will grow from 2,340 to 3,900 aircraft to 2043 and will subsidiary of HNA Aviation Technic, which is the sixth authorized
consist of 1,250 narrowbodies (<40 tons), 785 medium widebodies AEI Conversion Center in 2023, has five more 737-800SFs to deliver
(40-80 tons) and 810 large widebodies (>80 tons).

AEI
All very optimistic, with Airbus predicting a 4.6% CAGR over the
forecast period but the narrowbody freighter conversion market
is a difficult area at the moment, and for the next few years, says
Robert Convey, AEI senior vice president of sales and marketing at
Aeronautical Engineers, Inc (AEI). The company specializes in the
Boeing 737-400/800SF, Bombardier CRJ-200 SF and McDonnell
Douglas MD-80SF.
Lower production rates of new aircraft and technical problems
with LEAP and GTF engines means that there are very few
737-800 airframes available for conversion, that they have an
uneconomically high sale price and there is a huge shortage of
CFM56 engines, also inflating prices. In addition, the pandemic
demand bubble for freighters has burst. For the next few years,
he sees demand as being sporadic, a combination of airlines with
cargo operations converting their own passenger fleet or lessors
deciding to convert to keep their asset alive for a bit longer.
To illustrate the point, AEI’s forecast for 2023 was for
Demand for conversions may be sporadic for the next few years, says Robert
approximately 44 freighters, with the 737-800SF again accounting Convey, of AEI, due to a combination of airlines with cargo operations
for most deliveries, plus four 737-400SFs, four CRJ-200 SFs and converting their own passenger fleet or lessors deciding to convert to keep
their asset alive for a bit longer. AEI image.
four MD-80SFs. In reality, it was 28 aircraft - 18 737-800SFs,

16 Aviation Maintenance | avm-mag.com | Quarter Four 2024

and KF Aerospace in Canada has been working on three 737-800SF AEI says it will use
conversions for Air Inuit, two of which are in a Combi configuration. any slower periods in
Given the downturn in demand, the company is being cautious the coming months to
study the next potential
but using the time to study the next potential, with the 737-900 conversion candidates, with
and the CRJ 900ER as two most likely candidates. The -900 will the 737-900 and the CRJ
probably be first, with an agreement with Boeing hoped for by year 900ER as two most likely
possibilities. AEI image.
end, which would mean entry into service in the first half of 2027.

EFW
Jordi Boto, CEO of EFW, agrees that the narrowbody market is
difficult at the moment — the company has a P2F conversion for
the Airbus A320 and A321 developed in collaboration with ST
Engineering, with EFW holding the Supplemental Type Certificate.
In particular, airlines are having to keep A321 aircraft in
passenger service that were intended to be converted until those
delivery and engine problems are resolved, he thinks in 2026/7.
A problem for customers replacing Boeing 757s with A321P2F
is that they could face the need for an expensive overhaul on
an old aircraft. In addition, stricter noise regulations could limit
future night operations in Europe. There have been very few
cancellations to date but there have been several delays.
One of EFW’s customers is Azul Cargo in Brazil, which
received its first aircraft in October, with a second to arrive by
the end of the year.
Despite the pressures, EFW signed a MoU with MRO Japan (MJP)
to establish an A320P2F/A321P2F conversion line at Naha Airport training to ensure operational readiness and excellence. The first
in Okinawa, where air cargo is forecast to see a huge expansion. aircraft induction for conversion is foreseen to commence by the
Japan’s freighter and logistics market size is estimated to expand at a end of 2025.
CAGR of 4.2% between 2024-2029, with air freight being the fastest "We are excited to have MJP join our global network of P2F
growing market by mode of transport. The partnership in conversions conversion sites," said Boto. "Collaborating with experienced
will make the company Japan's first conversion site for the new- and well-backed aircraft solution providers like MJP supports our
generation Airbus narrowbody P2F aircraft. capacity for freighter conversions to capture opportunities in the
Under the contract, MJP will serve as a subcontractor for growing Japanese air cargo market."
EFW, providing third-party conversion services for EFW’s Airbus Takashi Takahashi, CEO, MJP, added, “We are truly happy that
A320P2F/A321P2F programs. The process of onboarding MJP as the new partnership between EFW and MRO Japan has been
EFW’s new modification site involves comprehensive trainings in established. It will be a significant step towards mutual growth
tooling, engineering, supply chain, industrialization and quality and prosperity for both parties. Our deepest gratitude goes to

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EFW for their cooperation and support. We are excited to work says there is some concern about feedstock as delays to the 777X
with the EFW team to initiate the first modification and move on could extend the in-service life of the 777-200LR and 777-300ER
to the next step.” that form the basis of their conversion program. Typically, these
The A330 market has a different dynamic, Boto says. This is aircraft have a service life of around 12-15 years before there is a
a new aircraft in the market, offering a much greater capability combination of heavy maintenance checks and a complete cabin
than the previous workhorse, the Boeing 767, with up to 23% and IFE/connectivity refurbishment. As those refurbishments could
more volume (A330-300P2F), 7% more payload and a 10% wider cost from $8 million to $15 million, he suggests that it does not
fuselage catering for 96in containers side-by-side. A seven-inch make economic sense to make that level of investment in aircraft as
wider door allows for the transport of 16-foot and 20-foot pallets. airlines are only buying 3-6 years of lift until new build Airbus and
The company has been able to offset the delays to some Boeing production catches up on the backlog.
extent by expanding in different areas. It recently started A380 In addition, each airline has its own distinct branding that runs
maintenance again, the first customer being U.K.-based Global through the interior, from seats and galleys to color scheme, which
Airlines, but it has other customers lined up and will expand makes it is more difficult and expensive to transition them to a
activities from 2025 onwards. There is a surge in very heavy and new operator. However, he comments, while the 777X delays have
complex 12-year inspections coming up, which is beyond EFW’s meant that airlines like Emirates, with a huge 777 fleet, have had
capabilities, but it can take advantage of a squeeze on hangar to make those investments to maintain their standards, those with
slots to carry out lighter checks. He points out that EFW will be smaller fleets cannot justify the expense.
one of few non-airline related MROs working on the type. Incidentally, Emirates Sky Cargo ordered a further five Boeing
Overall, progress has been good, with 18 conversions delivered 777Fs on order, having previously ordered five, while also has 10
in 2022, 28 in 2023 and a projected 30-35 in 2024 (the uncertainty 777-300ERs currently being converted into freighters by IAI BEDEK.
reflecting the narrowbody market again). That program should have been certified by now but appears, for
very obvious reasons, to have encountered some delays.
Mammoth He says determined cargo operators will locate and purchase
Brian McCarthy, VP of marketing and sales at Mammoth Freighters, aircraft where they can, with engines and spares support from the

INSIGHTS FROM THE BOEING

AIR CARGO FORECAST
BOEING’S LOOK AT AIR CARGO DURING
THE PERIOD FROM 2022 TO 2041 GIVES A
NUANCED LOOK AT THE MARKET FOR AIR
CARGO AND THE NEED FOR CONVERSIONS.
MORE ON THE BOEING.COM WEBSITE.
Multiple Drivers of Growth
A range of issues beyond cyclical economic trends influence air Outlook, the company anticipates the global freighter fleet (production
cargo market growth forecasts. Among them are modal competition, and conversions) will produce up to 2,610 new freighter deliveries in
globalization, market liberalization, and new air-eligible commodities. the next two decades. Of these, 890 will be production freighters and
Complementing the 2.6% long-term economic growth outlook, trade the remaining 1,720 will be converted freighters.
and industrial production will be key drivers for air cargo growth. We Specifically for freighter conversions, it is forecasting demand for
forecast that trade will outpace economic growth, increasing 2.8%, 1,720 converted freighters over the next 20 years to replace aging
and that industrial production will grow 2.2%, both annually, over the freighters and accommodate future growth. This includes 1,200
next two decades. These economic factors, as well as the regulatory narrowbody conversions and 520 widebody conversions.
and industry structure dynamics highlighted above, support Boeing’s While both maritime shipping and air cargo yields are normalizing as
forecast that air cargo traffic, measured in revenue ton kilometers, will capacity challenges recede, maritime yields may remain elevated due
grow an average of 4.1% annually from 2022 to 2041. to industry consolidation. In 2000, the top 10 containership operators
handled 62% of the world’s shipping capacity. At the end of the
pandemic in 2022, that share rose to 86%.
Modality Competition
Measured in tons of goods moved, the maritime transport industry is
much larger than the air cargo industry. In 2021, the world maritime Varying Requirements
industry carried an estimated 11.1 billion tons, compared to 60.9 Varying requirements drive a range of air cargo services. From an end
million tons of air cargo. By weight, 86% of the world’s maritime trade user’s perspective, general freight and express offerings are fairly easy
is in raw materials and other bulk items. Most of these commodities, to distinguish in terms of commodity and time definiteness. However,
such as oil, metal ores and grains, are low in value, not time sensitive, from a business-model perspective, the lines between express and
and shipped in specialized vessels. These cargoes cannot be directly general air cargo continue to blur. Traditional providers are expanding
compared to the high-value, dry commodities associated with air their time-definite offerings, while express carriers, freight airlines, and
transport. However, while air cargo accounts for less than 1% of the postal authorities often provide general cargo service. Ultimately, cargo
world’s trade tonnage, the high value of these goods means it is customers benefit from increased service options and lower prices, as
responsible for about 35% of the value of all globally shipped goods. competing services enter the market.
However, according to Boeing’s most recent Commercial Market

18 Aviation Maintenance | avm-mag.com | Quarter Four 2024

 Left: Jordi Boto, EFW CEO and right: Takashi
Takahashi, CEO, MJP shake hands after signing
a contract to partner for A320P2F/A321P2F
conversions. EFW image.

China and Southeast Asia. Advanced manufacturing and expanding

consumer economies — key building blocks for global trade — will
drive growth for these regions. Trade is expected to expand at 2.8%
on average over the next 20 years, with essential contributions not
only from South and Southeast Asia, but also from many developing
countries, as well as substantial, established traders like China.
Advanced economies remain foundational parts of the global economy.
While GDP is expected to grow at less than the global average, the
size and economic breadth of these markets makes them indispensable
as traders of advanced goods and services, as well as destinations for
the exports of many emerging economies.

Airline Business Models Vary

Airlines adopt business models tailored to specific air cargo markets.
Air cargo operators fall into four main categories:
• Belly-only operators provide air cargo capability within existing
passenger networks.
• Cargo specialists provide dedicated main-deck freighter capability
for general freight, charter operations, and specialized loading and
carriage capabilities.
• Combination carriers leverage both dedicated main-deck freighters
and the belly capacity of extensive passenger networks to provide
reliable air connections, particularly to and from home markets and
hubs.
• Express carriers operate main-deck freighter fleets of all sizes to
provide time-definite services as well as general air cargo capability.
Express carriers typically utilize standard body and medium-
widebody freighters to support their hub operations.
With air cargo traffic volumes now running near pre-pandemic levels,
and yields elevated, global air cargo revenues have reached all-time
highs. In 2021, air cargo revenues hit $170 billion, up from $100 billion
in 2019. Combination and all-cargo carriers have seen the largest
increases, with both segments roughly doubling their 2019 revenues
in 2021, while revenues for express and belly-only carriers increased
roughly 45% compared to pre-pandemic levels.
Over the next 20 years, global GDP is expected to grow 2.6% on
average. South Asia will lead the world with 5% growth, followed by

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 Mammoth has commitments for 29 -200LRMFs and six
relatively few part-outs that are occurring, but he warns that, if
-300ERMFs with airframes already designated and with
freighter demand is strong enough, those part-outs will decline planned start dates for conversions, the company says.
and could constrict surplus parts availability. Mammoth image.
However, Mammoth already has commitments for 29
-200LRMFs and six -300ERMFs with airframes already designated
and with planned start dates for the conversions. These will
take place at Aspire MRO in Fort Worth and at STS Aviation in
Manchester, U.K. 777conversion project by Kansas Modification Center (KMC) and
Identified customers are launch customer Jetran, which WERX, part of Wichita State University’s National Institute for
took Cargojet Canada’s four -200LRMFs early positions in Aviation Research.
the Mammoth program. Jetran has additional orders for 777- His experience shows that once a program is out there flying,
200LRMFs, while AviaAM Leasing has the six -300ERMFs and there is a tendency for one to become the standard, as happened
DHL has eleven -200LRMFs coming from Mammoth via Jetran. with the Boeing 757 during his time at Precision Aircraft Solutions,
Some of Mammoths customer commitments are undisclosed at based on payload/range, quality and reliability. There is room for
this time. two, but not three, 777 conversion providers, says McCarthy.
The first -300ERMF is in work at Aspire and the first two Another consideration is that the bow wave effect will also be
-200LRMFs at STS, with the second -300ERMF to be in work at seen here, so there is a need to be ready for 18-20 aircraft per
Manchester no later than January 1, 2025. He points out that year. Mammoth already has the capacity to build 24 cargo doors
having multiple aircraft under conversion simultaneously is more per year. There are five conversion lines in Fort Worth and two in
efficient as labor can be moved to the area of highest activity. The Manchester, each capable of around three aircraft per year, so 21
first 777-200LRMF cargo loading system was delivered by Collins aircraft in total.
Aerospace in July, while the door cut on the first -300ERMF was The next step is certification, with the master STC for the
completed at Aspire a month later. -200LRMF and an amended STC for the -300ERMF. The first
McCarthy says having such a backlog buys Mammoth some aircraft, a -200LRMF, should be ready for company flights in late
time to get new orders as it proceeds towards certification. One December/early January. Formal FAA light tests will follow in the
source of those orders might be airlines who are flying production first quarter which should yield FAA Type Inspection Authorization
777F alongside passenger aircraft, which gives them a degree of (TIA) within that quarter. The hope is certification in March, with
flexibility in having their own feedstock. the -300ERMF following in August. No certification work will be
Another reason that makes this a possibility is that next- done in the U.K., however, as the company is planning both EASA
generation freighters will be later than planned. It takes some and CAA validation of FAA STCs.
time to deliver the bow wave of initial orders before the The first -300ERMF is in work at Aspire, along with four -200LRs
production rate settles down to allow the introduction of new awaiting conversion. These will be followed by the first two
build freighters to the line, so the 777X freighter is some way -200LRMFs at STS, with the first in work and the second arriving in
off. He suggests that Airbus may be able to take off some of the early November.
pressure through A350 passenger aircraft deliveries, allowing 777 Depending on the market, a further conversion line might be
retirements for conversion — the Mammoth advantage is nearly established in the Asia Pacific region, where, he says, customers
the same amount of cargo for $100 million less. typically have a lot to say about where they would like to see
The potential total market is 200-250 aircraft in the forthcoming aircraft converted. If the business presents itself in the years ahead,
years, split between Mammoth, IAI BEDEK and the third Mammoth will not hesitate to establish a presence there.

20 Aviation Maintenance | avm-mag.com | Quarter Four 2024

Special Advertising Section
INDUSTRY LEADER
PROFILES
 highest-quality, reliable rolling element bearings — so why
Schaeffler Aerospace Repair settle for anything less than the quality and experience offered
by Schaeffler Aerospace? By working with us, you can lower
Services: your bearing replacement costs by having your bearings reliably
remanufactured by an OEM-approved manufacturer.
A Tradition of Excellence, Moreover, Schaeffler’s reconditioning capabilities are not just
Reliability and Sustainability limited to bearings: our MRO expertise extends to virtually any
aviation-grade rotating equipment on an aircraft — which is
When Charles Lindbergh something not many companies in the world can do.
completed the first solo, non-
stop transatlantic flight in 1927 A Few Words About Sustainability
in his now-legendary “Spirit Sustainability is an integral part of Schaeffler’s DNA — and
of St. Louis,” the propeller bearing reconditioning dovetails perfectly with that commitment.
shaft of the aircraft’s Wright-J5 Our production processes focus on energy efficiency,
“Whirlwind” engine was environmental compatibility, and conservation of resources.
supported by a cylindrical roller To that end, Schaeffler has laid the groundwork to achieve
bearing manufactured by a carbon-neutral production by 2030. At the same time, we are
Schaeffler Aerospace predecessor continuously expanding our climate protection ambitions, which
company. Of course, material we are increasingly incorporating into our entire supply chain.
advancements, design innovations and engine demands have
changed considerably since Mr. Lindbergh touched down safely in Schaeffler — We Pioneer Motion
Paris, but Schaeffler’s leadership in this market has never wavered. The Schaeffler Group has been driving forward groundbreaking
Today, Schaeffler Aerospace is a leading supplier to every major inventions and developments in the field of motion technology
engine manufacturer in the aviation industry. for over 75 years. With innovative technologies, products
Decades of diligent research and development work enabled and services for electric mobility, CO2-efficient drives, chassis
Schaeffler to be the first company to formally introduce the solutions and renewable energies, the company is a reliable
concept of infinite fatigue life to the industry in 1983. Since partner for making motion more efficient, intelligent and
then, it has been acknowledged that useful bearing service life is sustainable — over the entire life cycle. Schaeffler describes its
primarily limited by damage caused by environmental factors such comprehensive range of products and services in the mobility
as contamination, corrosion, overheating, etc. ecosystem by means of eight product families: from bearing
Understanding these factors is critical to designing robust solutions and all types of linear guidance systems through to
systems and — through expert diagnosis and repair — prolonging repair and monitoring services. With around 120,000 employees
the service life of today’s precision aerospace bearings. and more than 250 locations in 55 countries, Schaeffler is one
of the world’s largest family-owned companies as well as one of
Schaeffler Aerospace Repair Facilities Offer: Germany’s most innovative companies.
• Up to 70% cost savings vs. new.
• Engine manufacturer-approved repairs.
• Reduced inventory and carrying costs.
• Repairs performed to OEM-quality standards using OEM
equipment.
• Fast turnaround.

Bearing Remanufacturing: Control Costs Without

Compromising System Reliability
Schaeffler Aerospace provides remanufacturing services that
can help you reliably lower your total maintenance costs by
repurposing existing assets. Your bearings are restored back to
their original “as-new” condition using the same engineering
experience, manufacturing methods, production personnel and
testing procedures. Of course, in addition to lowering life-cycle
costs, bearing recondition also reduces CO2 emissions — an
important element of Schaeffler’s commitment to sustainability.
As a matter of course, Schaeffler Aerospace’s refurbishment
techniques always include refinishing the bearing’s raceways,
replating (or replacing) the cage and replacing 100% of the rolling
elements. All replacement components are manufactured to the
original new specification by our OEM-approved processes. Any
repurposed and remanufactured components undergo 100% non- Schaeffler
destructive testing (NDT). www.schaeffler.com
Today’s cutting-edge aerospace applications demand the

22 Aviation Maintenance | avm-mag.com | Quarter Four 2024

We pioneer motion

Control Costs
without Compromising System Reliability

You already know Schaeffler Aerospace as a leading OEM supplier to the rotary
wing aerospace industry. But did you know that we also offer industry-lead-
ing repair and overhaul services that can help your maintenance team ensure
supply chain reliability and control costs across a global network? Moreover,
Schaeffler’s reconditioning capabilities are not just limited to bearings: Our
MRO expertise extends to virtually any aviation-grade rotating equipment on an
aircraft – which is something not many companies in the world can do.

Schaeffler Aerospace is an FAA- and EASA-licensed repair station in the USA,

and a TCCA-, EASA- and CAAC-approved maintenance organization in Canada.
Our global footprint includes repair stations in Germany and China.

www.schaeffler.us
©2024
AirNxt offline. Whether your team is 30,000 feet in the air or stationed
on the tarmac, essential information is always at their fingertips.
Imagine preparing for a high-stakes chess match in an industry 5. Transparent Pricing
where precision meets complexity — but your pieces are Forget about hidden fees and complex negotiations. AirNxt
scattered, and your board is outdated. This is the daily challenge offers transparent pricing, ensuring you know exactly what
many aviation maintenance teams face: using legacy systems that you’re paying for.
feel like playing chess blindfolded. Try AirNxt, the next-gen MRO
software designed to bring order to this chaos and redefine how Why AirNxt Is the Future of MRO
aviation maintenance is approached. Unlike the traditional, clunky systems that require extensive
training and adaptation, AirNxt is built for the modern age. Its
What Makes AirNxt Different? development comes from a deep understanding of the aviation
Aviation maintenance has historically been stuck in the past, industry’s needs, guided by Mahmoud El Sawah, a seasoned
bogged down by outdated systems and manual processes that professional with over a decade of experience in MRO and CAMO
demand extensive training and lengthy implementation cycles. operations. Mahmoud and his team have shaped AirNxt as a
Teams often find themselves juggling expensive software only product that doesn’t just catch up with the industry's demands
to return to familiar but inefficient tools. AirNxt changes that but anticipates and leads them.
narrative by introducing an intuitive, AI-powered platform that
doesn’t just keep up with today’s standards — it sets new ones. What Does This Mean for Your Operations?
It empowers teams to work smarter, faster, and with unmatched Implementing AirNxt is like upgrading from a typewriter to a state-
precision. Built on a foundation of industry expertise, AirNxt’s of-the-art computer. You move faster, make fewer errors, and work
innovations are reshaping what’s possible in aviation maintenance. smarter. The platform’s AI-driven analytics provide real-time data
that allows you to make informed, proactive decisions. Maintenance
Key Features of AirNxt That Change the Game teams can finally focus on what they do best — keeping fleets
1. Instant Onboarding and No Training Required operational and safe — without the burden of managing outdated
In the time it takes for most legacy systems to reach their first processes. AirNxt equips your team with the tools to tackle
phase of implementation, AirNxt is already up and running. challenges head-on and optimize every aspect of maintenance.
With an intuitive user interface, teams can start immediately The future of aviation maintenance is here, and it’s more accessible
without extensive training. Say goodbye to months of than ever.
onboarding and hello to seamless integration.
2. AI-Assisted Data Import Get Onboard with AirNxt Today
One of the most arduous tasks in aviation maintenance is Why stay grounded when you can elevate your operations?
migrating historical data. With AI-assisted data import, AirNxt Whether you're managing an airline, an independent CAMO, or
automates this process, ensuring your data is integrated an engine shop, AirNxt equips you with the tools needed to move
accurately and swiftly, leaving more time for what really matters: forward confidently.
maintaining and optimizing your fleet.
3. Predictive Maintenance for a Proactive Approach
Reactive maintenance is a costly gamble. AirNxt’s predictive
maintenance tools harness the power of AI to foresee potential
issues before they happen. This reduces unexpected downtime
and extends the life of assets, saving both time and money. AirNxt
4. Electronic Logbook and Offline Sync
Maintaining compliance while keeping records accessible has Visit www.airnxt.ai to learn more and see how AirNxt can
never been easier. AirNxt’s electronic logbook automates data transform your maintenance operations.
recording and ensures it’s readily available, even when you’re

24 Aviation Maintenance | avm-mag.com | Quarter Four 2024

 Introducing
the 1st Next-Gen
MRO Software

In an industry where every moment counts, AirNxt redefines aviation

maintenance with next-gen MRO software. Say goodbye to outdated aircraft
maintenance systems and unlock efficiency with AI-driven insights, rapid
implementation, and predictive maintenance that keep your fleet a step
ahead. AirNxt’s user-friendly interface requires no training, while mobile
access ensures your data is always within reach. Designed by aviation
experts, AirNxt is the comprehensive MRO solution that propels you forward
with agility and confidence.

Transform your operations - Experience the power of AirNxt today.

https://www.airnxt.ai/ (+971) 4 244 2279 [email protected] linkedin.com/company/airnxt/

Elliott Aviation: 85+ Years
of Innovation and Excellence in
Aviation Services
Since 1936, Elliott Aviation has grown, evolved, adapted, and
innovated to meet the ever-changing needs of its customers. Our
world-class service company began quite modestly in the '30s
when Herb Elliott started Elliott Flying Service on a grass airstrip
in DeWitt, Iowa. We have since expanded to even better serve
our clients. and modifications to provide increased safety, performance,
Elliott Aviation is now a diversified aviation services company and utility for your aircraft and are continuously coming up with
with four U.S.-based locations. These locations include the technological innovations for total aircraft solutions.
company’s headquarters in Moline, Illinois, and its three additional Elliot Engineering Technicians, with years of design and
facilities located in Atlanta, Georgia; Des Moines, Iowa; and engineering expertise, operate multiple CAD stations to produce
Minneapolis, Minnesota. high-quality, professional wiring diagrams. Because of their
With over 85 years in the industry, Elliott is one of the longest- precision, Elliott Aviation wiring diagrams provide clear, concise
standing companies in aviation. Our services include aircraft instructions for our installers. Surprises are eliminated because the
sales (as Elliott Jets), avionics service and installations, aircraft design is often completed long before your aircraft ever arrives at
maintenance, FBO services, accessory repair and overhaul, paint, one of our facilities.
interior, parts, and aftermarket avionics sales. Complete documentation is provided for your aircraft, allowing
Elliott works on Hawker, Citation, Beechjet, King Air, Challenger, for permanent record-keeping and FAA traceability. Advanced
Phenom, Gulfstream, and Falcon airframes. Our experienced design and engineering systems also mean less downtime due to
technicians excel in maintaining light-to mid-sized jets and our ability to pre-engineer an installation.
turboprops; we offer expert solutions to meet your every need.
Turn Your Vision Into Reality
Nose-to-Tail Quality Elliott Aviation’s aircraft interior and paint design professionals
We are a factory authorized service center and repair station for work with you throughout the design process, learning
multiple airframes — our services are unsurpassed in the industry. preferences and molding a custom design.
With factory-trained technicians from Textron, Bombardier, Embraer, Whether you are remodeling an existing cabin or designing a
Cessna, Falcon, Gulfstream, and Challenger, our team has the completely new exterior finish, our designers aim to make the
training and expertise to understand your aircraft inside and out. process simple for you. We will provide options from an endless
At Elliott Aviation, we also provide competitive pricing for array of different colors, textures, patterns, and materials. Our team
engine overhauls. Whether an overhaul, upgrade, or exchange can even integrate a new cabin entertainment package with the
is the best option, our team will work with you to determine the help of our top-rated avionics staff. Additionally, we can re-engineer
right choice for your needs. Once the scope is determined, the your seat configuration with our in-house engineering team.
Elliott team will complete the engine removal and installation. From leather and fabrics to carpet and veneer, you have a nearly
Additionally, we will manage your project, providing you the endless variety of options to best suit your needs. Our expert
highest level of support with the engine supplier. designers will help you decide which options will transform your
With four U.S.-based locations, we have expanded our footprint interior into the luxurious, functional, and comfortable interior
to better serve you. These multiple facilities, located in the you’ve always wanted! Once specifications are determined, our
Midwest or the South, allow our expert technicians to provide a design professionals and master craftsmen provide the ultimate in
consistent, satisfying customer experience every time you visit. aircraft interior customization.

Cutting-Edge Technology Decades of Expertise

Elliott Aviation leads the industry in installation expertise, with Developing and delivering quality solutions ever since those
avionics upgrades that increase the safety, performance, and beginnings in 1936, Elliott is big enough to handle all your
value of your aircraft. Committed to delivering innovative aircraft aircraft needs, yet we are small enough to still provide the
solutions, we have been a world leader in gaining STCs for the personal touch you deserve. With state-of-the-art facilities
installation of high-technology equipment — FMS, Wi-Fi, TCAS, and equipment, proven processes, and highly-trained and
TAWS, EGPWS, Flat Panel Systems, and others — in a variety experienced technicians, we deliver world-class quality and
of turbine aircraft. And we have developed RVSM solutions for service customized to you and your aircraft.
a range of turbine aircraft. The level of sophistication in Elliott
Aviation’s engineering department keeps us at the forefront of
new STC development.
Our in-house, advanced engineering capability is a significant
value-added service we offer our customers. Our staff develops Elliott Aviation
STCs for new equipment installations and finds ways to interface www.elliottaviation.com
new technology with existing equipment. We work with systems

26 Aviation Maintenance | avm-mag.com | Quarter Four 2024

 A leader in Aircraft Solutions
S E R V I C E S

ACCESSORIES
LOCATIONS

AFTERMARKET PARTS
DSM

AVIONICS
FCM

MLI
INTERIOR
PDK

MAINTENANCE

PAINT

s a l e s @ e l l i o t t a v i a t i o n . c o m

w w w . e l l i o t t a v i a t i o n . c o m
Solutions for Better Aircraft
Data Management
Teledyne Controls, a leading provider of avionics and aircraft data
management solutions, built its name on innovative solutions that
collect, manage and deliver aircraft data more efficiently.
Teledyne’s proven technology and collaborative customer
relationships have revolutionized the way aircraft operators can
access, distribute and utilize their data to improve flight safety,
compliance, operational efficiency, and passenger experience.
The company offers an adaptable suite of products that includes
solutions for aircraft data acquisition and recording, wireless
data transfer, cabin air quality monitoring, secure software parts
loading and distribution, onboard networking, along with cloud-
based data analysis services. Combined together, these products
provide comprehensive data management solutions that leverage
aircraft data intelligence and create value for the operators.

Simplifying data distribution, while meeting today’s secure

dataloading requirements
One of Teledyne Controls’ standout offerings is their suite of
dataloading solutions, which are designed to streamline and
automate the distribution, storage, and management of Loadable
Software Parts (LSP) and databases across an airline’s operation,
while meeting today’s secure dataloading OEM requirements.
As aircraft continue to integrate powerful new systems and
networks into their design and the amount of software parts
increases, the software distribution process becomes more
complex. With more software parts being loaded, more often, the
opportunities for cyberattacks multiply.
Built from the ground up with security in mind, Teledyne
Controls’ latest dataloading products, the PMAT XS portable
loader and the eADL XS onboard data loader, represent a new In addition to these dataloading hardware solutions, Teledyne
generation of dataloading technology that meets the stringent Controls provides the LoadStar® Server Enterprise 3 (LSE 3), a
ARINC 645-1 requirements for OEM secure dataloading. comprehensive software parts management system that offers
With advanced features, such as built-in wireless connectivity, configuration control and load reporting capabilities, further
comprehensive validation of digital signature, and secure boot, enhancing the efficiency and reliability of the dataloading process.
they ensure the integrity of software parts and protects against Teledyne Controls’ commitment to innovation and customer
unauthorized access at every stage. collaboration has positioned it as a leader in the aviation industry.
Teledyne’s eADL XS was recently certified for use on the Boeing By providing advanced dataloading solutions, the company helps
737NG aircraft series and is in the process of being certified for airlines and aircraft operators to enhance the safety and efficiency
other aircraft platforms. of their operations.
Teledyne’s eADL XS offers several key benefits: With a global network of offices and field representatives,
• Advanced Security: Fully compliant with ARINC 645-1 security Teledyne Controls is dedicated to supporting its clients
standards, ensuring data integrity and robust protection against worldwide and providing them with the personal service and
cyber threats. attention they deserve.
• Wireless Connectivity: Built-in cellular and Wi-Fi connectivity,
for fully autonomous software part distribution with or without
Teledyne’s GroundLink® Wireless Quick Access Recorder.
• Ease of Integration: Designed as a plug-and-play
replacement for existing data loaders, simplifying the
upgrade process for operators. Teledyne Controls
• Enhanced Fleet Management: Integrates with Teledyne’s www.teledynecontrols.com
ground distribution systems to automate software configuration
control and load reporting. Headquartered in Southern California, Teledyne Controls
• Increased Onboard Storage: Expanded internal mass storage LLC is a wholly owned subsidiary of Teledyne Technologies
for onboard retention of software parts, facilitating reloading at Incorporated (NYSE: TDY).
any location and reducing risks of delays and cancellations.

28 Aviation Maintenance | avm-mag.com | Quarter Four 2024

 “Ladders Designed by Mechanics for Use by Mechanics.”

Aframes 3’ to 12’

LockNClimb designs and manufactures ladder stands

used by maintenance professionals to access service
points on Boeing, Airbus, McDonnell Douglas, Embrar-er,
Gulftstream, Bombardier, Dassault, Cessna and other
commercial and corporate aircraft. LockNClimb ergonom-
ic safety ladders are currently in use in leading MRO fa-
cilities around the world. SPECIFICATIONS: OSHA rated
300-lb. Special Purpose Ladders. • Free standing ladders
with yellow safety handrails and guard rails. • Engi-
neered to meet all applicable OSHA and ANSI standards. Cowl pylon ladders
• Patented industrial 6061-grade aluminum support
base, frame and slip-resistant platforms. • Extra wide
comfort treads and hard rubber wheels for rolling.
• Made in the U.S.A.

Contact:
Aircraft Ladder Sales
LockNClimb, LLC
2500 West Laurel Street
Independence, KS 67301
Office (620) 577.2577
[email protected]

Www.locknclimb.com
www.locknclimbaframes.com Rolling w/platforms
 Ergonomic Safety Ladders for Easier Aircraft Maintenance
LockNClimb designs and manufactures ladder stands used by maintenance
professionals to access service points on Boeing, Airbus, McDonnell
Douglas, Embrarer, Gulftstream, Bombardier, Dassault, Cessna and other
commercial and coporate aircraft. LockNClimb ergonomic safety ladders are
currently in use in leading MRO facilities around the world.

Rolling w/platforms Cowl pylon ladders Aframes 3’ to 12’ Fiberglass extension Tall step-through

GPU cord ladders Cargo bay ladders MiniPylons 4’ to 6’ Tall specialty Interior cabin

q Plastic top end caps Specifications

q Yellow safety handrails OSHA rated 300-lb. Special Purpose Ladders. • Free
q Yellow safety lean bar
standing ladders with yellow safety handrails and guard
q Yellow safety sides
rails. • Engineered to meet all applicable OSHA and ANSI
q Fixed booster step
standards. • Patented industrial 6061-grade aluminum
q Large service platform
support base, frame and slip-resistant platforms. • Extra
q Rubber bumper
wide comfort treads. • Made in the U.S.A.
q Extra wide treads
“Ladders designed by mechanics,for use by mechanics.”
q Patented support frame

q Anti-sway bracing
Contact:
q Full length handrail
Aircraft Ladder Sales
q Safety stickers
LockNClimb, LLC
q Wide stable base legs

q Replaceable brass feet

2500 West Laurel Street
q Hard rubber wheels
Independence, KS 67301
1+ (620) 577.2577
[email protected]

Watch videos at www.locknclimb.com

www.locknclimbaframes.com
Buffalo Shrink Wrap With a durable seal, shrink wrap provides long-lasting protection
and is simple to repair when the need arises after a tear. You can
As an industrial quality save your company with an investment in industrial shrink wrap
shrink wrap supplier, not only due to preserving your equipment but also because
we understand the of the low cost and minimal maintenance involved. Equipment
importance of protecting preservation doesn’t need to put a huge dent in your budget.
company assets from Do everything you can to protect your equipment; preserving it
harm. Therefore, we now is significantly cheaper than purchasing replacements down
provide a wide array the line. Allow us to be your industrial quality shrink wrap supplier
of wraps and tools to and provide your equipment with the protection it needs to
preserve your equipment ensure future functionality. For any further questions or business
and give it as much inquiries, don’t hesitate to give us a call or send us an email.
longevity as possible. With the right tools and the proper We’re happy to help you with whatever your company needs
application, you can protect your company assets from sustaining when it comes to shrink wrapping systems.
damage and make sure your equipment will see future use.
Depending on where you store your machinery, your assets may
be exposed to several threats that can damage it, causing lasting
harm and making expensive repairs or replacements necessary.
However, there are ways to add an extra layer of protection to
safeguard your machinery from environmental hazards and keep Buffalo Shrink Wrap
it safe during storage. Heavy-duty industrial shrink wrap is a great 9300 County Rd Suite B, Clarence Ctr, NY 14032-9530
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Heavy-duty shrink wrap offers a cost-effective way of protecting www.buffaloshrinkwrap.com
your machinery without requiring more expensive alternatives.

32 Aviation Maintenance | avm-mag.com | Quarter Four 2024

Vallair Visit us: Booth #256
MRO Middle East
One world of experience February 10-11, 2025
Dubai, United Arab Emirates
Vallair is a multi-disciplinary aviation company focused on
maximizing the life and value of aircraft, engines and parts.
We provide integrated support for mature aircraft, engines and
major components with our streamlined and complementary
business units that are founded upon engineering excellence,

One world
knowledge, and the delivery of quality services. These include
aircraft & engine MRO, trading & leasing, project management,
teardown of aircraft & engines, aerostructures, material
management, technical support and CAMO. These offer aircraft
operators and owners worldwide cost-effective solutions to of experience
extend the life of their assets or to dispose of them in an
economically beneficial and environmentally acceptable way.
Vallair is a leading player in the trading and leasing of A320
family, ATR and B737 aircraft, and a leader in the passenger to
freighter conversion market. Vallair is the sum of its parts, and our
teams work closely with customers, partners and suppliers around
the world to offer a single stop solution. Vallair MRO’s European
hub in France comprises two EASA/FAA accredited facilities in MRO & Painting
Châteauroux and Montpellier, which provide heavy maintenance Engines
programmes, painting and modifications. We also offer Aerostructures
narrowbody line maintenance capability to airlines and operators
Logistics
landing in Vatry airport near Paris.
For more than twenty years Vallair ASSETS has been a leading
participant in the trading and leasing of mature narrowbody
aircraft & engines for sale, lease, teardown and part-out. We have
a strong materials
management
division that
supervises Material Management
the repair and
Project Management
provision of parts
Trading & Leasing
to airlines and
Teardown
MROs worldwide.

Airbus A320 | A330/340

Boeing B737
ATR 42/72

Vallair
vallair.aero

Vallair is a historical founder of AFRA (Aircraft Fleet Recycling

Association). We offer aircraft operators and owners
worldwide cost-effective solutions to extend the life of their
assets, or to maximize value at end-of-life in an economically
beneficial and environmentally acceptable way.

Capabilities:
• MRO & Painting
• Engines
• Aerostructures
• Logistics
• Material Management
• Project Management
View our digital
• Trading & Leasing Luxembourg | Montpellier | Châteauroux | Vatry brochure here.
• Teardown

Read the latest issue online via avm-mag.com/current or avm-mag.com/back-copies Aviation Maintenance | avm-mag.com | Quarter Four 2024 33
Urgent: Fuel Tank Safety
Compliance Deadlines
Approaching!
Is your fleet ready to meet the upcoming mandated fuel tank
flammability reduction requirements?
• Airbus compliance deadline: February 2026
• Boeing compliance deadline: November 2026

INVICTA™ by Jetaire: Your Cost-Effective Compliance Solution

• Military-grade fuel explosion suppressant foam
• One-time installation, zero maintenance Jetaire's expert team guide you through a seamless INVICTA
• Compliant with FAA, EASA, AFAC, ANAC & TCCA for 25.981 installation process.
requirements Fly safer, smarter, and fully compliant with INVICTA.
• Installation in as few as 3 days
• No modification or altering of the FQIS
• Lowest total cost of ownership pathway to meeting regulatory
requirements
Why risk AOG scenarios when you can secure your flammability
reduction means technology from the company that pioneered
foam-based solutions for FTFR compliance today!
Jetaire Group
Act Now: Contact Jetaire to Learn More About INVICTA! www.jetairegroup.com
Ensure your fleet's safety and regulatory compliance. Let

34 Aviation Maintenance | avm-mag.com | Quarter Four 2024

 SYSTRATEC: Ten Years of 3. First manufacturer to incorporate exclusive laboratory
technology into industrial instruments, making available to the
Innovation and Precision in MRO sector a quality that was only available to the largest
aircraft manufacturers. These innovations translate into fewer
Aeronautical Weighing errors, less downtime and a better ROI.

In the demanding aircraft and helicopter maintenance sector, SYSTRATEC offers:

accuracy in the measurement of weight and center of gravity is • CARBON|aero: System of high-end portable weighing platforms
crucial. Innovative weighing systems by SYSTRATEC provide highly of 10, 20 and 30 tons, capable of measuring with extraordinary
accurate measurements of these mass properties, enabling load precision the weight and position of each aircraft wheel.
optimization and weight distribution strategies based on quality • Jack|WS: Optimal, cost-effective solution for the conversion of
data. SYSTRATEC's unique technology assists in the constant quest existing lifting jacks into a high-end aeronautical weighing and
to improve the sustainability of the aviation industry, pursuing the centering measurement system. Applicable to any aircraft, it
optimization of mass properties to achieve lower fuel consumption provides measurements in relation to the aerodynamic mean
and reduction in aircraft CO2 emissions. SYSTRATEC is the chord, without additional calculations.
undisputed leader in this field, offering state-of-the-art, highly • Static|WB: Perfect for measuring the weight and center of gravity
durable solutions that provide superior long-term value. of parts or assemblies in the quality laboratory. The best way to
certify static mass properties from the initial stages in the supply
The key to SYSTRATEC's success lies in its technological chain. The benefits of using SYSTRATEC include improved accuracy,
innovations: superior durability and continuous firmware upgradeability.
1. First manufacturer to incorporate carbon fiber into its weighing
platforms to develop ultra-rigid structures that eliminate
flexing and improve linearity and measurement accuracy, while
providing incomparably long service life.
2. First manufacturer to put on the market a portable weighing
platform capable of measuring, in addition to weight, the exact
position of the wheel on each platform with millimeter precision, Systratec
which greatly reduces uncertainty in critical aeronautical balance www.systratec.com
calculations in portable systems. General Phone (English & Spanish): +34 955 976 956
anuncio systratec-arte-final-v2 10/9/24 8:57

Aircraft on-jack Convert your traditional lifting jacks into a high-end

JacklWS SYSTEM weight & balance measurement system

Laboratory quality instruments for day-to-day operations in the maintenance hangar.

Superior Precision: High-end HBM® force sensors deliver laboratory-grade accuracy
and a long service life.

Enhanced Versatility: Accurately weigh almost any aircraft or helicopter, and achieve
consistent results across different locations.

Specialized Electronics: Our aircraftlREFERENCE electronics system is user-friendly,

eliminates external calculations, minimizes errors and ensures precise measurements.

Portable and Durable: Safe storage and transport with a military-grade Peli® case
that offers unmatched protection.

Contact SYSTRATEC today and go one step further in your Weight & Balance
Systratec measurement operations.

Read the latest issue online via avm-mag.com/current or avm-mag.com/back-copies Aviation Maintenance | avm-mag.com | Quarter Four 2024 35
 work area for technicians that is efficient.
Sonic: Tools for Sonic is trusted by some of the best in the aviation industry:
SpaceX, American Airlines, Piedmont Airlines, Pacific Southwest
Aviation Technicians Airlines, Alaska Airlines and more. Built to last a lifetime, we stand
behind every Sonic tool we make.
Sonic is the only tool company in North America that has Sonic’s Intermediate 263-pc Aviation Toolset: Sonic created this
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 By Richard Scarborough

MAJOR UPDATE TO AIRCRAFT

RECORDS AC
WHAT TO KNOW ABOUT THE PROPOSED CHANGES.

A
ircraft maintenance is a broadly defined labels, correctly identified aircraft parts and appropriate repair
term involving the care and keeping of station-specific signage. The question of workmanship rarely
aircraft. The industry continues to develop entered the conversation. They stuck to their checklist and ticked
best practices, and maintenance tactics off each block unless they received a formal complaint.
evolve directly proportional to aircraft I say this not to cast shade on FAA inspectors but to highlight
developments. Accurately documenting such how vital record-keeping is to aircraft safety. After an accident
actions is not to be taken lightly. It is often or incident, inspectors will review the aircraft's logbooks,
jested among maintainers that eventually, one would need to maintenance records, and airworthiness information. Refer
operate two aircraft in tandem; one to fly passengers and cargo to Section 7. Safety, Accident, and Hazard Reports of the
and the other to haul all the airworthiness paperwork. Aeronautical Information Manual (AIM), in which the Federal
Aircraft maintenance record-keeping is a serious business. Aviation Administration (FAA) aircraft safety includes maintenance
During my MRO ownership stint, the Feds spent almost the entire and record-keeping.
annual inspection visit pouring over work orders, looking for non-
compliance. Only when satisfied that the paperwork was in order, AC 43-9C - Maintenance Records
would they take a lap around the shop. While conducting this The FAA issues Advisory Circulars (AC) to inform the aviation
portion of the inspection, they typically looked for tool calibration public systematically of nonregulatory material. Unless

38 Aviation Maintenance | avm-mag.com | Quarter Four 2024

incorporated into a regulation by reference, the
contents of an advisory circular are not binding
on the public.
Advisory circulars are issued in a numbered
subject system corresponding to the subject
areas of the Code of Federal Regulations (CFR)
(Title 14, Chapter 1, FAA). In other words, ACs
keep the public informed concerning FAA rules
and regulations. And they are plentiful.
AC43-9C, entitled Maintenance Records,
is up for revision even after receiving two
change notices during its tenure:
• Change one, issued on April 7, 2017,
simply clarified regulatory references.
• Change two, issued on May 8, 2018,
updated paragraph 15 by adding
maintenance manuals to the list of
documents containing aircraft/powerplant
part life limits and reorganized the table
in Appendix 1, Airworthiness Directive
Compliance Record (Suggested Format).
• Revision D will be the first significant
overhaul of the AC since its inception in
1998.
The FAA granted an extension to
October 18, 2024, for comments on
the Advisory Circular AC No: 43-9D.
Currently in draft mode, this latest
revision would replace AC43-9C,
published on June 8, 1998. The Feds
use comment periods to get public
input on various issues.
The FAA Flight Standards Service,
updated September 11, 2024, provides details on the AC
revision, including 1) a summary, 2) a list of references, 3) documents
for downloading, 4) a comment portal, and 5) related information. on the proposed revision, stating, “The current AC 43-9 has
At first glance, the FAA may need to catch up on aircraft never been complete or either regulatory requirement, 43
record-keeping. However, aviation maintenance is making great or 91.” Even in 1998, AC43-9 lacked clarification on critical
strides in advancing electronic records, artificial intelligence aspects of aviation maintenance.
(AI), and predictive maintenance. With advancements moving at Sarah MacLeod, executive director of the Aeronautical Repair
unprecedented speed, updating maintenance records is timely. Station Association (ARSA), and I sat down to discuss Rev D. Her
The draft of AC43-9D, Maintenance Records, describes initial thoughts concerning the FAA’s revision were, “The FAA is
acceptable methods, procedures, and practices for demonstrating using this update to move the information currently contained
compliance with General Aviation (GA) maintenance record- in Order 8130-21 for maintenance providers. This AC will now
making and record-keeping. Why is that important? We shall contain the information for completing that form.”
discuss that shortly. At first glance, you will notice that Rev D Sarah is speaking of the AC introducing procedures for
weighs in at a hefty 20 pages compared to the 12 pages of Rev C. completing FAA Form 8130-3, Authorized Release Certificate,
I spoke with Ian Gregor, a public affairs specialist at the Office and Airworthiness Approval Tag for approval for return to service
of Communications for the FAA, who stated, “This is a draft under part 43. Sarah and I highlighted that the 8130-3 tag is
document for public comment. We can respond to questions typically completed by the type certificate holder on the left side
about the document when we finalize it.” Once the public or returned to service by a Part 145 Certified Repair Station on
comment period closes, the FAA reviews those comments, taking the right. She also commented that completing the FAA Form
the industry’s thoughts into consideration. When asked about the 8130-3 is in the AC, not Order 8130.21. The 8130-3 tag has been
period between closing the comments and the AC going live, in play for quite a while. The FAA is taking this opportunity to
Gregor responded, “It takes time for us to review, respond to, and include language to aid in completing the form. It is important to
possibly make changes as a result of comments we receive before note that every 8130-3 tag accompanying parts and components
finalizing an AC.” We agreed to reconnect after the new revision to the airplane becomes part of the aircraft record. In its
goes live. publication Common Logbook Mistakes, Business Aircraft Records
Ric Peri, vice president of government and industry affairs for lists Not Including the FAA Form 8130-3 Approval Tag with the
the Aircraft Electronics Association (AEA), shares his thoughts Logbook Entry When Components are Changed as one of the

Read the latest issue online via avm-mag.com/current or avm-mag.com/back-copies Aviation Maintenance | avm-mag.com | Quarter Four 2024 39
common errors. The 8130-3 is strikingly similar to the EASA Form make a difference? I spoke with Suresh Narayanan, founder and
1, thereby ensuring continuity among component airworthiness CEO of Jets MRO at DFW, and his answer was an emphatic yes.
recording and part traceability. After starting his business, Narayanan joined the National Business
MacLeod goes on to say that the AC needs to adequately Aviation Association (NBAA). "By surrounding oneself with like-
address roles and responsibilities. For example, 90% of the minded individuals, one has opportunities to gather good intel.
AC deals with 14 CFR Part 91 General Operating and Flight The NBAA badge is a sign of respect for the company. Our
Rules, as opposed to 14 CFR Part 43 Maintenance, Preventative industry’s strength is the self-policing credibility. There is no fake it
Maintenance, Rebuilding, and Alteration. 'til you make it."
Peri echoes that sentiment. He states, “The major change Organizations like ARSA, GAMA, and NBAA offer a place to
is specific to part 43 in that the FAA has included expensive gather and network with other aviation professionals. Actions
instructions on using FAA form 8130-3. Opening up this AC like the letter mentioned above are just the tip of the iceberg.
for comment is generating a proposal to separate the part 43 Advocacy is only effective in groups. There is indeed strength
maintenance records (combining AC 43-9 and 43.9-1) from in numbers. Other benefits include safety workshops, industry
creating a new part 91 record-keeping AC specific to the panels, and focus groups. The industry used this extended time to
requirement of part 91. This concept will better differentiate the investigate AC43-9D and review all the FAA’s proposed changes.
two regulatory requirements.”
Another addition to Rev D is section 22.2, Information Systems What Does This Mean for the Aviation
and Automation. The FAA introduces language stating, “With Industry?
advances in technology, the collection of the form data can be When I asked AEA’s Ric Peri what these changes mean for the
generated electronically in a variety of ways and then be stored aviation industry, he replied, “The proposed change is reasonably
that way.” They also mention AC120-78, Electronic Signatures, benign, mostly editorial changes.” That said, it is crucial to
Electronic Recordkeeping, and Electronic Manuals, which provide understand what the FAA requires, especially in record-keeping.
guidance that may be useful in developing such a system. This The 8130-3 does have particular nuances that maintainers need
is a step forward in electronically recording maintenance, paving to understand. For example, Block 8. of the form, labeled Part
the way for predictive maintenance and, eventually, the use of Number, indicates the Type Certificate Holders’ identifier for that
artificial intelligence (AI). For further information on AI, check component. This includes Parts Manufacturer Approval (PMA)
out the Aviation Maintenance article AI/ML is A-OK for aviation parts, regardless of type. A specific instance occurs when an
maintenance tracking and predictive maintenance published in Identicality by License PMA gives the manufacturer authority to
March 2024. produce and distribute parts that replace original equipment
manufacturer (OEM) parts. The replaced part or specification can
Why Request an Extension for Comments? be referenced in Block 12. of the 8130-3 labeled Remarks. Block
With the added material comes increased responsibilities. 12. can also include information such as technical publications,
Industry leaders felt the need for additional time to review the Supplemental Type Certificates (STC), Engineering Orders (EO), or
proposed changes. It is no secret that every time the FAA makes a other specific documented maintenance references.
change, the effects flow downstream, and everyone must comply. Sarah MacLeod and I also discussed the revision and its
Ignorantia juris non excusat. ramifications for owner/operators and pilots. She mentioned, “The
On August 9, 2024, eleven leading aviation trade organizations average pilot needs to understand the requirements of part 91—
sent a letter to the FAA requesting additional time to comment this AC currently contains that information. It is not the mechanic’s
on the Draft AC43-9D. The FAA quickly responded with an job to ensure maintenance records are complete; it is the owner/
extension. (ARSA) published an announcement stating in part: operator’s responsibility. That fact is not understood by many
This AC provides acceptable means of showing compliance with pilots who own and operate their aircraft.”
general aviation record-making and record-keeping requirements The industry group working on the issue will propose to
according to parts 43 and 91. Though not regulatory, it provides a separate the requirements for maintenance providers to
method, not the only method, and the industry continues to push complete maintenance and inspection records correctly from the
the FAA to carefully align its guidance with the regulations. information owners and operators of aircraft subject to part 91,
Some of the entities credited with the letter include, but are not which are required to obtain, maintain, and make available to the
limited to: government. In other words, AC 43-9 would be directed solely at
• Aeronautical Repair Station Association (ARSA) the maintenance providers' requirements of part 43, and a new
• Aircraft Electronics Association (AEA) AC would be directed at part 91 records. The bottom line is this
• Aircraft Owners and Pilots Association (AOPA) revision principally deals with the guidance of the FAA 8130-3
• General Aviation Manufacturers Association (GAMA) form and language concerning electronic record-keeping.. Many
• National Air Transportation Association (NATA) Certified Repair Stations have already deployed the 8130-3, and
The letter contains the complete list of those requesting the many more have adopted electronic records. The FAA has simply
extension, and mentions form 8130-3 clarification, bilateral updated AC43-9 to bring it current with standard industry practices.
agreements, and maintenance implementation documents. Now that the comment period is closed, the industry will
The entities mentioned above constitute only five of the follow the pattern as the FAA collects, reviews, and determines
industry leaders petitioning the FAA to extend the review period appropriate action for the intel it gathered. In many ways, aviation
of AC43-9D. Please download the letter and keep a copy in your maintenance has come a long way since the first version of AC 43-9
digital toolbox. These organizations work tirelessly to ensure safe launched on February 2, 1975, but the bottom line remains the
and efficient operations. How important is their role, and does it same: Document what you do, nothing more, nothing less.

40 Aviation Maintenance | avm-mag.com | Quarter Four 2024

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 By Mark Robins

INNOVATIONS IN
DENT DETECTION
NOT JUST COSMETIC, AIRCRAFT
DENTS REQUIRE ATTENTION
AND SOME INNOVATIVE
SOLUTIONS CAN HELP.
42 Aviation Maintenance | avm-mag.com | Quarter Four 2024
 8tree tools are calibrated under
ISO17025 — the highest standard
a metrology device can achieve.
8tree says as a result, dentCHECK
measurement results are traceable
to national standards and cannot be
manipulated. 8tree images.

debris (FOD) like hailstorms, loose objects, small rocks, bird strikes
and even accidental impact with service vehicles during loading
operations. Regardless of their origin, Leonard Buck, marketing
and business development manager at 8tree, Constance, Baden-
Württemberg, Germany, says, “Dents are safety critical since they
influence the structural integrity of the aircraft. Any dent has to be
assessed prior to continuing aircraft operations.” Airports, airlines
and maintenance crews must be aware of dents and their origins,
and take the necessary precautions to minimize them via proper
training, procedures and maintenance programs.

Dent Detection Methods

A
There are procedures and equipment in place for MRO engineers
ircraft dents happen. While some dents may to find, measure, evaluate, document and repair dents on aircraft
have minimal effects, others can damage skin, but it’s not always easy. Dent detection via visual inspection
thin aircraft skin and compromise the is tedious, time-consuming and subject to human factors. They
aircraft’s structural integrity and aerodynamic can be located in hard-to-reach areas of the aircraft with complex
performance via the damaged area that is curved geometries or on leading edges, not always clearly
pushed in from its normal contour. Varying in distinguishable even by trained engineers. Also, inspection can
size and severity, dents can range from minor occur at height and in challenging conditions, outdoors, where
indentations to more significant distortions of the aircraft’s surface. light and weather can interfere. Because dents can be smooth and
Dents on an aircraft’s surface can disrupt the smooth flow of without well-defined boundaries, with a depth often lower than
air over the wings’ fuselage and other surfaces. These disruptions 1 mm, they can be difficult to detect.
can increase air resistance, resulting in decreased lift, increased Buck explains that there are three distinct, different methods for
drag and reduced fuel efficiency. Dents can trap moisture and dent assessment:
lead to corrosion. Furthermore, they can shorten fatigue life and • Traditional Tools (ruler, flashlight, depth-gauge and pen).
contribute to the propagation of cracks. Failing to repair a dent “This is the manual inspection method. Very time-consuming
in time can result in non-compliance with aviation regulations, and error-prone. It’s industry knowledge that ‘you get 10 results
leading to fines, aircraft grounding or other penalties. if 10 people measure the same dent’.”
Dents can result from old age and also impact with foreign object • General Purpose 3-D Scanners. “3-D scanners require

Read the latest issue online via avm-mag.com/current or avm-mag.com/back-copies Aviation Maintenance | avm-mag.com | Quarter Four 2024 43
 panels etc., can be inspected with dentCHECK. Double-curved
and highly curved surfaces are almost impossible to measure by
hand (referring to the ‘guesswork’ statement again).” dentCheck
has 1-Click 3D dent-mapping with real-time visual feedback
providing go/no-go damage inspection through augmented
reality. It can be used at the line, in the hangar, on the tarmac or
in AOG situations.
Computer vision (CV) is an application of artificial intelligence
(AI) that trains computers to identify, interpret and track objects
in photos and videos. The technology is primarily driven by
Zeiss says they have products recognizing patterns that repeat themselves over a given set of
that offer scanning, probing, data. For inspection purposes, AI can detect dents automatically
and tracking in a single system,
a scalable field of view and on an aircraft, which could take a human worker up to hours to
high precision. Zeiss image. inspect, while trying not to lose focus on the task.
Jake Bauer, senior data scientist at Striveworks, Austin, Texas,
significant surface preparation (stickers applied on the surface) says, “CV models are trained on ‘ground truth’ data: properly
and produce datasets and point clouds, which must be post- labeled examples of what the analyst expects to encounter in the
processed in specialized software and demands the expertise of real world. If an analyst is using AI to review complex geometries,
highly trained metrology personnel.” then those same complex geometries need to be part of the
• 1-Click 3-D Dent-Mapping Tools. “Application-specific model training. Striveworks pairs data scientists with customer
designed tools developed for the needs of mechanics and subject matter experts to better understand the nuances and
engineers. This tool contains a projector that displays the dent challenges in manual workflows. Together, they can create an
dimensions directly on the surface i.e., augmented reality.” optimal training dataset for a complex task like dent detection. A
• AR-enabled 1-Click 3-D Dent-Mapping Tools. “Application- CV model optimized for complex geometries and curved surfaces
specific designed tools developed for the needs of mechanics will outperform general CV models at the same task.”
and engineers. Using Augmented Reality (AR), the tool projects
the dent dimensions directly on the inspected surface. Mechanics AI and Dent Detection
will always receive instantly actionable results with the click of a AI has indeed provided real improvements in efficiency for aircraft
button. That’s what is needed on the line or in the hangar.” dent detection. Striveworks worked with a leading Fortune 500
Despite these tools’ dent-detection benefits, Buck believes that logistics company to create CV models — fine-tuned on imagery
while “Dents are highly safety-critical and aviation (maintenance) of aircraft dents — to help inspection teams identify dents and
is a highly regulated field … when we’re looking at dent process vast amounts of imagery.
measurements, many airlines and MROs are still relying on guess “Inspection teams using AI were able to find 27% more dents
work. Industry knowledge and studies show that traditional dent and work through images 50% faster than by doing the work
measuring is nothing but guesswork.” manually,” Bauer says. “These improvements allow teams to
However, Buck adds that there are tools available today to solve review vastly more aircraft surface in a shorter period of time,
this issue. All 8tree tools are calibrated under ISO17025 — the an obvious benefit when entire fleets are grounded following
highest standard a metrology device can achieve. “The dentCHECK hailstorms. Because of the complicated challenge of teaching
measurement results are therefore traceable to national standards machines how to identify dents in photographs, advanced
and cannot be manipulated (thinking of compliance — big issue),” ensembling i.e., majority voting’ and data preprocessing
he says. “Any mechanic can operate the tool after a few minutes techniques are needed to add resilience.”
training. The AR-enabled dentCHECK tool was purposely designed When using AI to perform dent detection, Bauer believes
for dent-mapping on aircraft. The projection of instantly actionable specificity is key. “This starts with capturing data that is as similar
results on the aircraft surface is a giant leap for any airline/MRO/ as possible to what would be expected during an actual aircraft
OEM operation and for passenger safety.” inspection. Using the exact same type of aircraft, lighting, paint
Levis, Canada-based Creaform’s VXintegrity–Aerospace, is color, camera sensor, camera angle, etc., for model training will
dedicated 3-D visualization software designed to assess and improve a model’s ability to correctly identify dents during a real
characterize dent damage on different aircraft components, sizes inspection. There is no substitute for expertise when it comes
and surface finishes. Its guided workflow approach simplifies the to safety and inspection. While AI can recommend locations of
measurement extraction of 3D scan data and obtains the exact possible dents with high accuracy and speed up the process, a
dimensions required for the assessment. More accurate and faster trustworthy inspection should always have a human in the loop.
than traditional methods, the software limits operators’ impact on Ultimately, the safe maintenance of aircraft requires a well-trained
measurements and shortens the time needed to generate final inspection crew.”
reports, providing airlines with comprehensive data on issues that
require further analysis. Drones and Dent Detection
Improvements in drone technology have allowed analysts
Complex Geometries and Curved Surfaces to capture dent imagery faster and at less expense. “Drone
Complex geometries and curved surfaces have been known to be photography provides a critical AI input, both to tune CV models
the bane of aircraft dent detection, but that’s changing. Buck says to perform optimally on the task of dent detection and during
it’s becoming less difficult. “Inlet cowls, leading edges, acoustic actual inspections,” Bauer says. “Tuning models on the same

44 Aviation Maintenance | avm-mag.com | Quarter Four 2024

 Donecle is a Toulouse-based aircraft manufacturer that has developed
autonomous aircraft inspection UAVs. The company offers single UAVs and
swarms of UAVs to visually inspect the exterior of airliners. Donecle image.

sensor data (drone altitude, camera angle, image sensor, etc.) They will complement the handheld measurement capabilities. “The
that is used during actual inspections improves the performance first IRIS dentCHECK dent-mapping drones are being delivered to
of models. When any changes occur with the environment or the end customers. The IRIS dentCHECK is the ‘flying version’ of
sensors, the dent-detection models can quickly be retrained on 8tree’s handheld dentCHECK dent-mapping tool. It is the result of a
the new, real-world imagery to improve performance.” partnership between Donecle and 8tree.”
Buck predicts drones used in dent detection represent the future.

Avionics Support Group, Inc.

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Read the latest issue online via avm-mag.com/current or avm-mag.com/back-copies Aviation Maintenance | avm-mag.com | Quarter Four 2024 45
 By Joy Finnegan

RHINESTAHL AND HYDRO COMBINE TO FORM

POWERHOUSE RH AERO, INTRODUCING NEW
LANDING GEAR EQUIPMENT

B
ack in April of this year, Rhinestahl acquired field, supporting our OEMs and customers. And so, when you
HYDRO Aero. Now the two companies bring that great engineering capability together with practical
have merged to form RH Aero. The newly applications for customers, we think that's really where the
rebranded, combined company touts sweetness curves, right? We create something really differentiated
capability across custom-designed ground from the market. So that's the synergy.
support equipment (GSE), OEM-licensed
engine and airframe tooling and 26 global service centers as AVM: Talk about the current supply chain situation and how your
well as engineered solutions for OEMs, MROs and operators newly combined company can help.
across the globe. The two companies say they have a globally
diverse workforce of more than 850 skilled professionals and Moeller: With the combination of the two companies RH Aero
unprecedented supply capacity. Aviation Maintenance editor-in- now has, by far, the leading supply capability in the industry for
chief, Joy Finnegan, sat down with the new president and CEO, the products and services that we offer our customers. We've
Anthony Turner, and Dieter Moeller, chairman, to discuss how been working really hard over the last two years because we saw
things are going with the combining of these two companies and the ramp coming, right? I think that's one of the things that we do
their continued development of new and innovative solutions for really well, and I think sets us apart.
their customers.
AVM: The ramp coming out of the pandemic?
AVM: Why did these two companies decide to come together?
Turner: Yes. We understood we had a pretty good view of what
Anthony Turner: We set out to create a powerhouse that's we thought was going to take place. So, we started working
going to be able to provide levels of service and support, and on capacity, capability and development early. We started that
products that just haven't been available to our customers out process two years ago. We were here, we were ready, and we're
there before. Through the acquisition, by combining Rhinestahl’s prepared to meet the needs of our customers. Our objective is all
engine OEM licenses and HYDRO’s highly skilled service centers, about reliability, making sure we're ready for our customers and
we have become expertly positioned to support OEMs, MROs, they've got a reliable source for the products and service they
and operators across the globe. With more than a century of need. Our expectation when customers are dealing with us is
experience delivering reliable full life-cycle solutions, we are they're not hearing a lot about supply chain challenges, because
setting the standard in comprehensive life-cycle solutions for we're taking care, we're ahead of the wave.
aviation support equipment and services.
AVM: Talk about supporting your customers.
AVM: What's it like to acquire a company and merge two
companies? Moeller: The way the industry is today, everything is just in time.
Schedules are hypercritical. We've really developed a reputation
Dieter Moeller: So first I'd say it's a lot of fun, right? I mean, these for when a customer calls us, they know that they can expect if
things aren't always easy. I think there's great alignment from a this is a critical AOG-type situation, we've got somebody on the
values perspective in these two companies and these two teams. way as soon as the phone is put down. With having the in-region
Turner: The transaction was done because of the complementary sites normally we'll have somebody there that afternoon to take
nature and the commonality and values. Two high-quality care of them. And for customers today, that type of support is
companies that believe in their products, their brands and critical. We recently announced four new in-house manufacturing
really believe strongly in high levels of customer support. The and service centers opening in Q4 2024 and Q1 2025: Hong
geographic complements, the product and service complements Kong, Chengdu, China, Hyderabad, India, and Jeddah, Saudi
across each of the companies, the relative strengths and Arabia. Standard capabilities across all locations include
weaknesses. This goes back to the question you asked earlier, inspection, testing, calibration, repairs/overhaul, recertification,
which is the service. There's great strength in the history of test of electrical equipment, modification of tools, local customer
HYDRO, of product development and innovative solution design. support service, pressure measurement and load testing.
And I would say Rhinestahl's historical strength technically has Turner: Combined with GSE and airframe tooling, RH Aero offers
been about the use of the practical application products in the a complete portfolio of end-to-end service and support for more

46 Aviation Maintenance | avm-mag.com | Quarter Four 2024

 transport, enabling transport on standard pallets, without the
need for special handling or exceptional transport measures.

AVM: Tell us more about your COBRA system and how it helps
engine changes go quickly.

Moeller: It allows us to change engines out within hours, which is

something that used to take days.
Turner: The COBRA system basically is a purpose-built cradle
Dieter Moeller, Chairman Anthony Turner, electronic system that is able to take the engine off at the angle it
New President and CEO needs to be taken off and to be replaced. And it's able to do this
in a way that is secure and safe with much less time than the old
way of doing this.
than 100,000 tools in our installed base. This service is provided Moeller: It can be up to about an 80% reduction in time. This
by technicians located in 26 service centers in 10 countries. Our kind of plays into the scarcity of qualified labor, right? The lack of
strategy is to have qualified technicians located in-region for technicians in the market, which is not going away. It's going to
our customers to drive market leading turn-times and customer get worse. All of these things that used to take multiple people,
service. Using our Readiness Hub tooling inventory system and these products reduce the skilled manpower to do these types of
our Managed Services program, our Readiness Managers provide procedures. And given the lack of people in this field that's going
an unprecedented level of collaboration and service through our to be crucial for customers.
on-site, in-your-shop approach to conducting tooling management
and partnering with OEMs and MROs. AVM: How do you encourage innovation?

AVM: Why had these things not been available before? Turner: It's about being with your customers, because the best
product and service ideas come from the needs of the customers.
Turner: It was a matter of capability and the size. It's a critical mass And you can't really learn about these problems unless you're
issue with customers today asking for much more in-region support. spending time with customers. Voice to customer is critical. It's
With our level of support, which has always been at a very high level, key. We're very much a customer-first organization, and we really,
being able to do that at customers' facilities just requires an awful lot really put an emphasis on our team being with our customers,
of resources. And with this combination, we do have the resources to understanding their environment, the challenges they face. That's
be able to go and supply that footprint around the world. where the best ideas come from.

AVM: You mentioned high levels of support in-region. Talk about AVM: What can customers expect from this new powerhouse in
what that means to this company. the future?

Turner: It means being able to basically be the experts in aviation Moeller: We are well on our way through the integration process
support equipment and services for our customers and handle and bringing the synergies of both companies to the combined
that for them. They don't have to worry about that anymore. organization. We've done that symbolically through our rebranding
We're taking care of it for them. We're able to reach out to effort of RH Aero being consolidation of the two, Rhinestahl and
customers around the world and take care of customers at 26 HYDRO, groups, and within our leadership structure and the
major service centers. Then we've got a hub and spoke network organization. I've moved my position from being president and CEO of
where we've got a lot more reach even than in those 26 centers. the organization to being CEO and chairman. We put Anthony in and
just recently announced that he is the new president of RH Aero which
AVM: RH Aero has just unveiled new landing gear equipment, the sets us up for the next generation. Another step toward supporting
MLGTMULTI-2. This is a solution specifically designed to enhance our customers worldwide. We are really excited about that.
the removal and installation of main landing gears on common Turner: From the company itself, customers are going to see the
widebody aircraft. It is designed for the Airbus and Boeing wide broadest capability in support equipment-related services in the
body passenger and freighter fleets. You say this landing gear market. They're going see the highest level capacity and they're
change equipment is designed for a safer, faster and more cost- going to see the most innovative solutions coming from our
effective operation. Tell us about the advanced features of it that company. We're pretty far out ahead of this race. Our plan is to
are designed for safety and efficiency. create more distance from our competitors.
Moeller: Take a look at our history. I've been with the company
Turner: It enables quick and secure trunnion disconnection now 34 years, and throughout those 34 years, the times when the
thanks to its maneuverability and flexible design. The ergonomic organization, and our ability to serve customers, has been at its
handheld control panel makes for user-friendly operation. The highest, were those times that we were experiencing the strongest
MLGTMULTI-2 electrically controlled, high-precision movement growth. Those things go hand-in-hand because our people are
provides significant advantages and ease of use compared to really excited about being in a strong growth environment. I think
the traditional processes. Ground-based operation eliminates the there's so much more opportunity to take care of customers than
need for cranes or on-wing work, significantly increasing safety what has been done in the past. And I think with where the industry
during the process. Additionally, the system is optimized for easy is going, that's going to be more and more important.

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 By James Careless

THE STATE OF MRO

TECHNICAL TRAINING:
A CONVERSATION WITH
CAE'S SHAUN KULDIP
Shaun Kuldip,
CAE

A
ccording to the training firm CAE, the competencies on two distinct tracks: Specialist and People Leader.
demand for new MRO technicians will hit With three levels of achievement — Certified, Advanced, and Master
the half-million mark in less than a decade. — trainees can reach a Master Technician status in less time than in
To understand the impact of this demand previous Master Technician career development programs.
on the aircraft technician training industry,
Aviation Maintenance spoke with Shaun AVM: What are the trends driving technical training for MROs
Kuldip, global leader of CAE’s Maintenance these days?
Training Centre of Excellence. In this exclusive interview, Kuldip Kuldip: There are multiple factors contributing to the increased
explores the trends driving MRO technical training these days, the demand for maintenance technicians. One is the increase in
new teaching products that CAE is bringing to market, and what’s the average age of the technician workforce leading to waves
coming next in this training space. of retirement, which was accelerated by Covid. The loss of one
highly experienced technician cannot be simply replaced with one
Aviation Maintenance: For context, please tell us about CAE’s new technician entering the field.
work in aviation training. A seasoned technician in business aviation, with decades of
Shaun Kuldip: CAE, the company that trains the most pilots in experience on the job, is most likely certified to support, on
the world, operates over 70 civil aviation training centers globally. average, four different aircraft types. In the short term, it would
Known for its innovative approach, CAE trains pilots and aircraft often require four new technicians to replace the one. In the long
maintenance technicians. We also train air traffic controllers and term, it would take many years for one new technician to gain the
commercial aircraft cabin crew. same level of on-the-job experience as the ones retiring, creating
an ever-growing bottleneck.
AVM: The demand for new MRO technicians going forward is
astounding. What is CAE doing to address their varied training AVM: What can be done to address this problem?
needs? Kuldip: The first step in overcoming some of these challenges is
Kuldip: Our 2023 CAE Aviation Talent Forecast predicted a need exposure. We need to promote aviation maintenance to teens in
for 402,000 new maintenance technicians industry-wide by 2032. the pre-college years to better attract the next generation of new
As a result of the critical need for maintenance technicians we are aircraft technicians. This is crucial for long-term recovery.
developing training programs that will spool up technicians more In the interim, the industry must do a better job at retaining
efficiently, leveraging new technologies. talented and experienced aviation technicians and attracting
As part of CAE's Ready to Lead Program, we offer a variety experienced technicians from the military. These veterans could
of courses tailored towards aircraft technicians to help them provide a much-needed boost to the business aviation sector,
improve their leadership skills and support career advancement. however too many are not made aware of the possibilities and
This includes CAE's Aviation Interpersonal Management opportunities that exist for them and seek alternative career paths.
(AIM) course, which gives students the skills and knowledge Training providers such as CAE also need to produce new and
required in managing people and projects, finance, legal issues, innovative ways to accelerate a new student's ramp-up time to
communication, and many other business responsibilities. become an "effective" technician that can contribute sooner. How
CAE teaches entry-level aircraft maintenance technician courses do we cram four years of training experience in two years? This
and in-depth initial training courses on specific aircraft. This includes includes leveraging new technologies (VR) that resonate with the
the latest and most technologically advanced business aircraft being youth of today to better retain knowledge.
built today. Courses range anywhere from a three-day "REALCase"
course to five-plus weeks for a full aircraft tip-to-tail initial course. AVM: Why is the aviation industry finding it difficult to recruit
Our Master Technician Program is geared towards organizations entry-level aircraft maintenance technicians, and what can be
and individuals who seek to attain the highest standards of technical done to address this problem?
excellence and professionalism in business aircraft maintenance. The Kuldip: I think the industry is unfortunately seen as less attractive
innovative program allows technicians to enhance their skills and for new job seekers. Since Covid, the graduation rates at aviation

48 Aviation Maintenance | avm-mag.com | Quarter Four 2024

maintenance technical schools are not keeping pace with the monitoring and evaluation. Our CAE Rise™ technology uses
numbers retiring. Metrics-Based Insights (MBI) and telemetry data to show pilot
A lack of incoming technicians for many years and the instructors objective data during live training, allowing them to
retirement of a significant number of long-time technicians has focus on evaluating soft skills.
created the perfect storm. The reality is that most future aircraft The technology, which CAE has developed for both civilian and
technicians are not training yet today, which is a problem. military pilot training, also provides analytics to proactively detect,
[Fortunately] Media coverage of the current pilot shortage has and ultimately address, emerging safety trends. The technology
benefited maintenance technicians as an awareness around the uses analytics to identify trends and optimize training programs,
pending workforce shortfall has increased. This is now a topic that ultimately enhancing the quality of training and ensuring pilots are
all operators are interested in seeing solved and is a topic that better prepared. CAE Rise is currently only being used for pilot
government workforce development programs are looking to address. training but could potentially be used in maintenance technician
More marketing and media coverage of the improved wages, training and other programs in the future.
number of open jobs, and career progression potential for aircraft
maintenance technicians will be necessary to continue to bring AVM: What will the impact of AI and VR be on the training of
eyes to the industry and convince more people to take up the aircraft maintenance technicians?
training to begin their path to a license. Government grants or Kuldip: As CAE gains more experience on how to deliver training
scholarships will also bring in necessary attention and give more with these new tools, student retention will continue to improve.
access to those willing to join the industry. Additionally, training times will start to decrease, and this comes
at a time when technician demand is growing due to many factors
AVM: What new approaches is CAE considering to train the next in the aviation industry. Getting technicians trained and back to
generation of aircraft maintenance technicians? the hangar floor in less time is a key objective for CAE and VR is
Kuldip: CAE is exploring new learning methodologies, such one of many tools that will help us do just that.
as Just-in-Time, that takes long and complex type-specific
maintenance initial courses and breaks them down into easily AVM: How is the MRO market responding to these new training
accessible shorter courses that offer training when the technician tools?
is ready. This gives technicians time to learn new concepts and Kuldip: Customers love being able to bring an aircraft inside of
practice them on the shop floor before returning to training to the classroom environment. The special orientation that VR allows
learn the next area. This predictable cadence of training offers makes objectives such as component locations and removal and
technicians a clear line of sight on what they will be learning and installation tasks much simpler to deliver.
how their career will evolve. Students enjoy being able to access parts of the aircraft that
they normally would not be able to during routine maintenance.
AVM: Where does virtual reality (VR) fit into your training systems? They can explore the maintenance computer and evaluate faults
Kuldip: CAE is deploying the latest in VR technology and that they may not have on their aircraft.
simulation via the cloud on our latest Gulfstream and Dassault OEMs have come to expect this level of technology from us
maintenance programs for the G500/600, G650, and 6X that and push us to develop further VR applications.
allow technicians to experience the entire aircraft in a virtual
environment. We are coming up on the one-year mark since we AVM: Finally, what's new and on the horizon for aircraft
started using VR. maintenance technical training?
As we gather feedback from our customers on VR, the intent is Kuldip: Modern day aircraft have advanced technologically
to roll out across other aircraft platforms. Technicians can perform whereby integrated systems now talk to each other and can
maintenance tasks in this virtual environment in several teaching to a great degree, assist technicians in the troubleshooting of
modes, including an evaluation mode that allows technicians aircraft issues in an automated manner. One such system is the
to measure their skills independently. An instructor-led mode "Centralized Maintenance Computer", a highly complex system
also exists that will guide students through the various steps to that is difficult to teach without the use of simulation.
perform certain troubleshooting tasks. Technicians can experience CAE's high-tech capabilities are an important element to
the aircraft with no fear of damaging expensive parts or putting effectively teach the maintenance of today's modern aircraft. The
wear and tear on sensitive interior components. Maintenance use of these tools is integrated through many of our courses so
tasks that are safety sensitive or cost prohibitive are now available that the technician is very familiar with its use by the end of the
for technicians to practice as much as they require. class. Trying to work on a modern-day jet without knowledge of
how these onboard systems work is all but impossible for almost
AVM: What about adding artificial intelligence (AI) to your VR any modern-day aircraft.
training systems? While CAE Rise could potentially be used in other programs in
Kuldip: The future convergence of AI and VR represents a the future, it is currently only being used for pilot training.
transformative synergy which will revolutionize how we build
immersive training and skills-development solutions within the
aviation industry. As these technologies continue to evolve in
tandem, the convergence of AI and VR is poised to redefine the
boundaries of human interaction and pave the way for new and
innovative applications across diverse domains within the aviation
industry. Aviation is one of the industries where the adoption of
emerging technologies is accelerating.
An example of how we may converge AI and VR for
maintenance technician training is to improve performance

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 By James T. McKenna

EXPANDED OFFERINGS IN
MAINTENANCE, INSPECTION
TOOLS, PARTS, OPERATIONS

S
uppliers, MROs and operators have mechanics and inspectors use the device to assess wear, scratches,
announced new developments in their dents, corrosion and other damage that occurs in aircraft engine
maintenance activities and laid out plans operation. It can assess features ranging from 0.1 inch to 100 mils
for expanding services that support repair, deep or tall. The measurements—completed in seconds on the
overhaul and inspection efforts. shop floor or on-wing — quickly determine whether critical parts
The latest developments range from new are safe for use or need to be discarded.
offerings of inspection and maintenance For engine parts makers, the 4D InSpec’s short measurement-
tools and software, parts manufacturer approval (PMA) and to-measurement time of — about a second — means they
supplemental type certificate (STC) initiatives for business jets can save hours over tedious preparation of rubber replicas for
and expansion of airline spares inventory and maintenance base feature assessments.
operations. Here’s a rundown. “The aerospace industry has some of the most stringent parts
specifications found in any macro-scale manufacturing process,”
4D InSpec AT’s Use in Engines Grows 4D Technology general manager, Erik Novak, said. The selection
4D Technology’s 4D InSpec AT fully automated, non-contact, 3D of 4D InSpec “validates the precision of our measurement and the
surface gauge will be measuring specifications, damage and wear great value added by its speed and versatility.”
on more aircraft engine parts following a recent customer order. Based in Tucson, Arizona, 4D Technology is a leader in
The 4D InSpec AT is compatible with automated systems like innovative products for measuring surface quality and defects on
robot arms and rotary tables. Combined with a robot arm, the precision surfaces. The company is a wholly owned subsidiary of
gauge provides a substantial increase in productivity and precision Onto Innovation Inc.
for customers measuring edge break, chamfer and round-off
on aerospace parts, the company says. With the gauge rapidly Snap-on Kit
positioned by a robot arm, the 4D InSpec software can take Reliably Moves
a measurement, calculate adjoining planes and determine the Impact Tools
shape, curvature and slope of the remaining surface after edge Snap-on Industrial’s
break and round-off. (The 4D InSpec AT also can be used as a Portable Heavy-Duty
handheld instrument.) Impact Sets help
This allows customers to check critical specifications of aircraft technicians reliably
and engine parts like airfoils, disks and bearings, as well as transport their impact
to prevent crack tools on the work site.
propagation and The 25-piece, heavy-
ensure proper fit and duty cordless impact set with portable storage (425IMCT) comes
seal. The 4D InSpec with an assortment of tools, including:
can help overcome • A 17-piece shallow-impact socket set with Snap-on Flank Drive
difficulties in measuring technology, which provides superior gripping power while
the numerous callouts guarding against rounding of fasteners.
on an engineering • A ¾-inch drive swivel-ball impact universal joint.
drawing, such as hard- • ¾-inch drive extensions of three inches, seven inches and
to-reach inside corners, 10 inches.
areas between blades • An 18-volt, ¾-inch drive Monster Lithium cordless impact
and samples that must be wrench set, with 1,300 foot-pounds (1,763 Newton-meters) of
perpendicular to adjoining bolt breakaway torque and 1,000 foot-pounds (1,355 Newton-
edges. meters) of working torque; the set includes two Lithium 5.0
In addition to measuring amp-hour batteries and a charger.
machined edges, aircraft • A sturdy, all-weather-resistant Pelican case with a collapsible

50 Aviation Maintenance | avm-mag.com | Quarter Four 2024

 handle and rugged wheels. expertise led to the development of the patented EnduroSharp
• Two-toned (red and black) colored tool control foam to securely line of aircraft maintenance tools.
house the tools. For more information, visit www.endurosharp.com.
The kit weighs 72.13 pounds (32.72 kilograms). The case measures
24.8 by 19.7 by 11.9 inches (62.99 by 50.04 by 30.23 centimeters). Streamlight Unveils Brighter Tactical Light
The kit is sold through Kenosha, Wis.-based Snap-on’s franchisees The high-
and its company-direct, distribution and web-based channels. For performance lighting
more information on the kit, visit https://b2b.snapon.com/. maker Streamlight
has introduced the
Performance Plastics Expands EnduroSharp ProTac HL6, the
Line newest and brightest
Performance addition to its line of
Plastics has tactical lights.
expanded its The ProTac HL6
EnduroSharp features a multi-function, easy-access head switch that allows for
line of aircraft one-handed operation of the light’s momentary, variable intensity
maintenance tools, or strobe modes. It also has an anti-roll face cap and a sure-grip
adding Torlon rubber sleeve.
sealant removers, The system includes a charge cord and two Streamlight SL-B48
three EnduroSharp 5000 milli-Amp-hour lithium-ion rechargeable battery packs with
adhesive reamers an integrated USB-C charge port.
and the Deluxe EnduroSharp Scraper Blade Sharpener for keeping “The ProTac HL 6 is like a handheld flood light, allowing users
those and other tools well honed. to see all around them while also providing a powerful beam reach
The sealant removers are non-metallic, spiral single-fluted to put more light on a target at a distance,” said Michael F. Dineen,
cutters designed to cleanly remove non-metallic debris such as chief revenue officer of Eagleville, Pa.-based Streamlight. He said it is
cured sealants, fillers, coatings and adhesives from larger surface the ideal light for many uses, including troubleshooting repairs under
areas such as fuel tanks with no abrasion to the underlying paints, low-light conditions.
primers or metal substrates. Designed for use with a power drill, The ProTac HL6’s high setting delivers up to 5,300 lumens and
the cutters have a hex-drive mounting feature. 80,000 candela over a range of more than 1,850 feet (566 meters). On
The cutters are made of Torlon, a material that itself can be medium, it produces 1,500 lumens, 23,000 candela and a 990-foot-
re-sharpened. This makes the cutters and other tools made of plus (303-meter) beam distance. On low, the light provides 450 lumens
Torlon reusable. and 6,700 candela over nearly 540 feet (164 meters). Streamlight said
The multi-fluted, straight-walled adhesive reamers can be used the ProTac HL6 can run for 12 hours and 30 minutes on low to two
to remove debris such as cured sealants and adhesives from hours on high; in strobe mode, the light can run for four hours.
fastening and bushing holes in metallic or composite structures The ProTac HL 6 measures 10.5 inches (26.7 centimeters) in length
without damaging the structures. Originally offered in nine sizes, and weighs 1.3 pounds (0.6 kilograms) with two SL-B48 rechargeable
the company has added three sizes to the lineup: the TAR 171 batteries. It is rated IPX7, making it waterproof to one meter for 30
(0.171-inch diameter, straight-fluted, ¼-inch hex drive), TAR 234 minutes. The light also is impact resistance-tested to 3.28 feet (one
(0.234-inch diameter, straight-fluted, ¼-inch hex drive), and TAR meter). It comes with Streamlight’s limited lifetime warranty.
296 (0.296-inch diameter, straight-fluted, ¼-inch hex drive). The For additional information, call +1-800-523-7488, visit streamlight.
reamers are also made of Torlon and are reusable. com or connect on facebook.com/streamlight, Instagram.com/
The Deluxe EnduroSharp Scraper Blade Sharpener features a streamlightinc or LinkedIn/company/streamlight-inc.
diamond abrasive material surface for sharpening and restoring
a factory edge to all EnduroSharp consumable products. The New Part 91, 135 Maintenance Tracking
diamond abrasive material itself can be resharpened. Software
Performance Plastics developed all EnduroSharp aircraft Miami-based WingWork
maintenance tools with the University of Dayton Research Institute has launched its cloud-
(UDRI), and the Air Force Research Laboratory (AFRL) to provide based maintenance
reliable and dependable material removal tools for military and tracking platform for Part
commercial aircraft maintainers. 91 and 135 mechanics.
EnduroSharp tools are approved for use by the U.S. Air With a modern, intuitive
Force, Marine Corps and Navy and military organizations of interface, the WingWork
many other nations. platform is designed
Performance Plastics is a Pexco company. Headquartered near for ease-of-use and
Atlanta, the Georgia-based Pexco is a custom precision injection comprehensiveness, the
molder of high-performance, tight-tolerance thermoplastic company said, allowing
components. It specializes in geometrically complex precision operators to spend more
parts that consist of chemically inert materials. The company’s time fixing and less time

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clicking. The initial launch has features covering maintenance
tracking, work orders, inventory control, invoice generation,
logbook ingestion and data entry. WingWork said its goal is to
empower operators to better forecast maintenance events and
associated costs, reducing downtime spent servicing their aircraft.
WingWork said it tapped a team of 50-plus industry advisors,
including maintenance personnel at operators and seasoned
aviation experts, to develop the platform.
"Our network of advisors has been a crucial element to our
success,” said CEO Matt Castellini. “They give us invaluable
feedback on building a world-class tool to power the modern
aircraft mechanic." King Air turboprops for decades. PWI FAA-approved LED
The WingWork team plans further product expansion driven by aircraft lighting upgrades can be purchased direct or through
customer feedback. its authorized dealer and distribution network. Contact PWI at
"The maintenance industry is ready for a 21st-century solution +1-316-942-2811 or [email protected].
that will utilize cutting-edge technology widely adopted in other
industries," WingWork chief technology officer Karthik Srinivasan Skyservice Targets G280 Gogo Galileo STC
said. "We want to develop best-in-class software to help the Skyservice Business Aviation is developing an STC to install Gogo’s
maintenance industry make the transition from relying on manual Galileo HDX on Gulfstream G280s by early 2025, giving operators
processes to harnessing the power of next-generation technology." access to the latest high-speed in-flight internet solutions.
For more information, visit www.wingwork.com. "The demand for reliable, high-speed in-flight connectivity is
higher than ever," said Skyservice president and CEO Benjamin
PWI Gets PMA for Citation LED Step Lights Murray. “Our development of this STC for Gogo Galileo HDX
Wichita, Kan.-based PWI, is a direct response to meeting that demand with cutting-edge
Inc. is bringing the long solutions." There are about 240 of the popular super-midsize
life and low power-draw G280 in operation worldwide, the company said.
efficiency of LEDs to Gogo Business Aviation’s latest innovation, Gogo Galileo is
Cessna Citation jet steps designed to provide operators worldwide with global, high-speed,
with its receipt of PMA on in-flight internet and low-latency performance for business aircraft
components for that Textron from light jets and turboprops to the largest business jets. The
Aviation series of aircraft. compact HDX aims to leverage Eutelsat OneWeb's enterprise-
The Citation models grade low-Earth-orbit (LEO) satellite network, which is designed
covered by the PMA include for mobility to deliver low variability and consistent performance
the Citation II, the 550 Bravo, across all routes globally.
the S550 II/SP, the Citation V Mississauga, Ontario-headquartered Skyservice aims to get
560, the Excel 560XL and the the G280 Gogo Galileo HDX STC validated by Transport Canada
650, as well as the Citation Civil Aviation (TCCA), the FAA, the European Union Aviation
III, VI and VII. Safety Agency (EASA), the National Civil Aviation Agency of Brazil
The new LED step light (ANAC) and the U.K. Civil Aviation Authority (CAA).
replaces the original incandescent step lights in the door of the Operators can contact Skyservice (www.skyservice.com) to
Citation (part number 6900163-000 and Textron part number submit a purchase order for the Galileo HDX, which is designed to
1021LIGHT). No aircraft modifications are required, according be an easy upgrade to any AVANCE system (AVANCE L3, L5, LX5,
to PWI. It says the single PWI LED part number (6910163-003) SCS). Installations are planned for 2025’s first quarter. A special
simply screws into the steps using the original mounting holes. The promotional rebate of $25,000 is also available for a limited time
installation reuses the original aircraft lighting wiring and runs on to current Gogo customers operating a legacy air-to-ground
the aircraft-supplied 28 volts. All PMA-approved LED cabin lighting system (ATG 1000, 2000, 4000, 5000) when installing AVANCE
systems have a three-year PWI warranty. SCS and HDX, Skyservice said.
The door-mounted step light is designed to resist cabin ingress
and egress wear-and-tear. The new design uses impact-resistant AvAir Broadens Lufthansa Technik
polycarbonate lens material to deliver long-term durability. It also Component Pact
offers greater liquid and contaminant resistance to such common AvAir has broadened its partnership with Lufthansa Technik
elements as deicing fluid, rain, snow and mud, PWI said. Component Services, acquiring more than 1,600 overhauled
“This new LED step light puts a nice touch on one of the first wheels and brakes from the German MRO’s excess inventory.
things you notice when entering the cabin: the doorsteps,” said Chandler, Ariz.-based AvAir’s inventory acquisition includes
PWI president and CEO Robi Lorik. The PMA installation “adds a components for Bombardier CRJ700s and 900s, Embraer E190s
level of safety and convenience that passengers appreciate before and the complete range of Boeing and Airbus models, including
they are seated.” the 787 and A350. AvAir said all parts are serviceable and come
PWI has been an original equipment manufacturer of fluorescent from Lufthansa Technik's material pool and aircraft teardowns.
cabin lights for the Citation as well as other business jets Their transfer from Lufthansa Technik facilities in Germany to
(Dassault Falcons, Gulfstreams, Challengers and Learjets) and AvAir's Chandler warehouse is expected to be complete by early

52 Aviation Maintenance | avm-mag.com | Quarter Four 2024

 February 2025.
The transferred material
from this transaction is to
come with dual or triple
release certification (the
FAA, EASA and/or the Civil
Aviation Administration
of China) from Lufthansa timely customer deliveries, the company said. It is to include a
Technik and with a 12-month hangar that accommodates two 777s or four 767s. The facility
warranty, AvAir said. Most is also to have a ground service equipment staging area,
parts were maintained underground foam containment, a loading dock and service
by Lufthansa Technik's entrance, backup generator capability, HAZMAT storage, a large
component maintenance, repair and overhaul organization. water tank, offices and employee parking.
"We are thrilled to expand our inventory with such a diverse The expanded apron, covering 50 acres (20.2 hectares), will
range of wheels and brakes, enhancing our offering for our include eight new aircraft gates and three new maintenance gates.
customers," said AvAir president Brandon Wesson. "Our That will allow DHL to accommodate more aircraft and handle a
partnership with Lufthansa Technik has been invaluable, and we larger volume of shipments.
look forward to the new opportunities this acquisition will bring." The $292-million facility is expected to be fully operational by
The companies established their long-term aftermarket sales January 2026.
agreement in 2020, with AvAir acquiring more than 9,000 line- DHL's KCVG hub currently operates on 194 acres (78.5
replaceable units from Lufthansa Technik's global material pool. hectares) with 67 aircraft parking gates and 6.4 million square
In 2022, AvAir expanded its inventory by purchasing 9,000 more feet (594,579 square meters) of ramp area. The heart of DHL
aircraft components. Express’ Americas network, it handles 117 daily flights and a
Lufthansa Technik is to receive a share of proceeds from resold fleet of 64 aircraft and connects customers from more than 220
components under a profit-share arrangement. countries and territories worldwide to every corner of the U.S.
For more information about AvAir, visit AvAir.aero. KCVG is one of three DHL global superhubs, with the others in
Hong Kong and Leipzig, Germany.
DHL Express Building New Maintenance "Over the last several years, we have been enhancing our
Base network capabilities with newer and more fuel-efficient aircraft,"
DHL Express in October began constructing a state-of-the-art said Rob Hyslop, EVP Global Aviation, DHL Express. “This new
facility and expanded aircraft apron in its global hub at the facility complements those efforts with additional space for more
Cincinnati/Northern Kentucky International Airport (KCVG) to aircraft to be maintained at the same time.”
improve the express shipper’s ability to maintain its Boeing 737, DHL expects to hire 300 more employees to support the new
767 and 777 fleets. maintenance facility as part of a recently developed joint venture
The 305,000-square-foot (28,335-square-meter) facility in between DHL Express and Kalitta Air, a long-time DHL service
Covington, Ohio, will enable more efficient repairs, reducing partner. Kalitta Air and DHL will jointly oversee the critical aircraft
aircraft downtime and improving service reliability to support maintenance activity at the new facility.

54 Aviation Maintenance | avm-mag.com | Quarter Four 2024

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Securing Defense Information:
CMMC 2.0's Impact on
Cybersecurity Requirements
By Frank Balonis

T
he Department of Defense has established a critical one- phase, allowing organizations to adapt to new requirements while
two regulatory punch for protecting sensitive defense limiting broader impact.
information through its Cybersecurity Maturity Model
Certification 2.0 Program. The first component, 32 CFR Part 170, • Phase 2
takes effect December 16, 2024, with the second component, • Begins 12 months after Phase 1 start.
48 CFR Part 204, following in 2025. This coordinated regulatory • Where applicable, solicitations will require Level 2 Certification
approach addresses a stark reality: malicious cyber activity costs with assessments conducted by CMMC Third Party Assessment
the U.S. economy between $57 billion and $109 billion annually, Organizations (C3PAOs).
with the defense industrial base facing persistent targeting from • Projected 673 C3PAO certifications during this phase, enabling
sophisticated threat actors. the assessment ecosystem to mature methodically.
The Council of Economic Advisors calculates these attacks
could burden the U.S. economy with up to $1.09 trillion in costs • Phase 3
over a decade. To combat this threat, CMMC 2.0 creates new • Begins 24 months after Phase 1 start.
requirements for more than 220,000 defense contractors who • Where applicable, solicitations will require Level 3 Certification.
process, store, or transmit sensitive defense information. 32 CFR • During this phase, DoD projects completion of 2,252 C3PAO
Part 170 establishes the program structure and security standards, certification assessments.
while 48 CFR Part 204 implements contractual mechanisms through
the Defense Federal Acquisition Regulation Supplement. • Phase 4: Full Implementation
• Begins 36 months after Phase 1 start.
Three-Year, Four-Phase Implementation for • All solicitations and contracts will include applicable CMMC Level
requirements as a condition of contract award.
Defense Contractors • Annual C3PAO assessments will reach 4,452, covering
CMMC 2.0 establishes three distinct control levels based on approximately 20,395 small entities and 9,148 large entities.
information sensitivity. Level 1 requires 15 basic cybersecurity
controls from FAR 52.204-21 for protecting Federal Contract Understanding the CMMC 2.0 Certification
Information, focusing on fundamental practices like access control
and basic system security. Level 2 mandates all 110 security Verification Process
requirements from NIST SP 800-171 Rev 2 for protecting Controlled CMMC certification scoring varies by level, with each tier requiring
Unclassified Information, encompassing comprehensive controls progressively more rigorous verification by C3PAOs. Level 1
across 14 domains including access control, incident response, employs a straightforward met/not-met scoring system for its
security assessment, and system integrity. Organizations must 15 basic safeguarding requirements from FAR 52.204-21. For
achieve a minimum score of 88 out of 110 points. Level 3 builds Level 2, organizations must achieve a minimum score of 88 out
upon Level 2 by requiring a perfect score of 110 on NIST SP of 110 possible points based on NIST SP 800-171 Rev 2 security
800-171 Rev 2 controls plus 24 additional enhanced security requirements, while Level 3 demands a perfect Level 2 score plus
requirements from NIST SP 800-172, including advanced threat successful implementation of 24 additional enhanced security
monitoring, 24/7 security operations center capabilities, and cyber requirements from NIST SP 800-172.
incident response teams that can deploy within 24 hours. C3PAOs, accredited by the CMMC Accreditation Body, serve
The DoD’s implementation strategy spans four distinct phases as the primary assessors for Level 2 certifications, conducting
over three years: comprehensive evaluations that have replaced the previous
• Phase 1: Initial Implementation self-attestation model. During assessments, C3PAOs examine
• Begins at 48 CFR Rule Effective Date. both technical implementations and organizational processes,
• Where applicable, solicitations will require Level 1 or 2 including detailed reviews of system configurations, security
Self-Assessment. policies, operational procedures, and control implementations. The
• DoD estimates 1,104 small businesses will participate in this initial assessment process includes documentation review, system testing,

56 Aviation Maintenance | avm-mag.com | Quarter Four 2024

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personnel interviews, and direct observation of security practices. will soon determine their ability to compete for defense contracts
The CMMC Accreditation Body maintains oversight of C3PAOs involving protected information.
by establishing assessment standards, monitoring performance,
and ensuring consistent evaluation methodologies. Additionally, the Frank Balonis is chief information security officer and senior VP of
Defense Industrial Base Cybersecurity Assessment Center provides operations and support at Kiteworks, with more than 20 years of
another layer of quality control by conducting regular evaluations experience in IT support and services. Since joining Kiteworks in
of C3PAO capabilities and performing high-priority assessments. 2003, Balonis has overseen technical support, customer success,
Organizations seeking certification must submit assessment results corporate IT, security and compliance, collaborating with product
and maintain current status in the Supplier Performance Risk and engineering teams. He holds a Certified Information Systems
System, with a senior company official required to affirm continued Security Professional (CISSP) certification and served in the U.S.
compliance annually or when security changes occur. If deficiencies Navy. He can be reached at [email protected].
are identified during assessment, organizations may achieve
conditional certification through Plans of Action and Milestones
(POA&Ms), which must address permitted gaps within 180 days.

180-Day Conditional Certification Pathway for 10 Compliance Essentials for Cybersecurity

Addressing Security Gaps and Data Protection
CMMC 2.0 permits limited use of Plans of Action and Milestones In today’s complex regulatory environment, organizations must
(POA&Ms) for Level 2 and 3 certifications. Organizations meeting keep pace with diverse, often stringent security and privacy
minimum scoring requirements can achieve conditional certification requirements. Here are 10 key compliance areas companies
by addressing permitted deficiencies within 180 days. This flexibility should prioritize to bolster defenses and reduce regulatory risks:
supports transition while maintaining security standards. POA&Ms 1. Navigate Complex Regulations: Regulatory landscapes,
must address specific remediation timelines, resource requirements, including GDPR and HIPAA, demand strict data
and technical solutions for each identified gap. protections tailored by industry and region, requiring
continuous monitoring and adaptation.
Governance and Supply Chain Obligations 2. Create a Data Inventory and Classification System:
Establishing a detailed inventory helps identify and
The regulations establish clear contractual implications through categorize sensitive data, allowing for targeted protections
48 CFR Part 204, expected to be published in 2025. Contractors across data life cycles.
must achieve their required CMMC level before contract award. 3. Adopt Strong Data Protection Practices: Implement
Contracting officers cannot award contracts, exercise options, technologies like encryption and access controls to secure
or extend performance periods without verification of current
data during storage and transfer, essential for compliance
certification. Prime contractors must validate subcontractor
and security.
compliance based on the sensitivity of information in the supply
4. Manage Third-Party Risks: Mitigate vulnerabilities
chain, ensuring security requirements flow down appropriately.
introduced by vendors through thorough due diligence,
The certification ecosystem includes several oversight
routine security audits, and compliance monitoring.
components. The CMMC Accreditation Body establishes
5. Develop Incident Response Plans: Ensure rapid response
assessment standards and monitors C3PAO performance. The
to data breaches, with protocols for regulatory notification,
Cybersecurity Assessor and Instructor Certification Organization
containment, and recovery in line with GDPR’s 72-hour
manages training programs and maintains certification standards.
rule and other timelines.
The Defense Industrial Base Cybersecurity Assessment Center
6. Follow Data Retention and Deletion Guidelines: Set
conducts high-priority assessments and validates C3PAO
policies for retaining data only as long as necessary and
capabilities through regular evaluations.
securely deleting outdated information to reduce exposure
and meet legal requirements.
Oversight Framework 7. Promote Cybersecurity and Privacy Awareness: Regular
Organizations must submit assessment results and maintain training sessions raise awareness among employees,
current status in the Supplier Performance Risk System. A senior emphasizing the importance of protecting sensitive data
company official must affirm continued compliance annually and following compliance best practices.
or when security changes occur. The DoD requires current 8. Enhance Cyber Resilience: Develop business continuity
certification or self-assessment results for each contractor and disaster recovery plans to sustain operations during
information system processing sensitive defense information, with cyber incidents, incorporating regular drills to test and
specific documentation requirements for system boundaries and improve resilience.
security implementations. 9. Maintain Governance Through Audits and Reporting:
CMMC 2.0's dual regulatory framework creates comprehensive Routine audits and transparent reporting practices
cybersecurity enhancement across the defense industrial base. The bolster governance, helping organizations demonstrate
phased implementation balances security imperatives with practical compliance and refine security protocols.
considerations about industry readiness and assessment capacity. 10. Follow a Comprehensive Compliance Checklist: Use
As both regulations take full effect, they establish increasingly a regulatory checklist to stay proactive, addressing
robust protection for sensitive defense information while specific regulations like CMMC 2.0, ensuring continuous
maintaining supply chain vitality. Organizations must prepare now improvement in compliance and security readiness.
for these mandatory requirements, understanding that certification

58 Aviation Maintenance | avm-mag.com | Quarter Four 2024

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