REPORT
COMPLETION AND REFURBISHMENT
BESPOKE INTERIORS ARE SOMETIMES THE ONLY WAY TO GO To kick off the New Year, we look at the different sides of the completions business, from refurbishment and design to component supply, and cover the big names and projects of 2013. By Ivan Veretennikov
B
CUSTOMIZED
According to Duncan Aviation (top), today’s buyers are looking for turn-key, readyto-go aircraft.
espoke interior design is sometimes the only way to go in Business Aviation. For a head of state or a large corporation it means outfitting the aircraft to their particular mission, while a wealthy family turns to their favorite studio to make sure that the airplane feels like home and has everything necessary on a long journey. Owners seeking to custom-build their airliners have a choice of brilliant designers and experienced completion centers. In many cases the two even come together. Believe it or not, the problem is to find a slot: major outfitters are booked far ahead, and first deliveries of green Boeing 787 aircraft will mean longer queues. Design and completions of the most expensive, spacious, and capable byliners are, however, just one side of this business (and one that seems to be particularly stable judging by the conversations we’ve had). Refurbishment of pre-owned aircraft – either to sell it on at a higher price or to enjoy modern conveniences such as up-to-date avionics and cabin management systems – is another section of the market that sees steady demand. There are enough aircraft aged 15-20 years that are in perfectly good condition, but feel dated due to an old-fashioned interior or dials in the cockpit. In a challenging economy many opt to upgrade their existing asset rather than seek financing for a new one and wait for the old one to sell (which for midsize and large-cabin jets may well take over a year).
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2013 was a steady year for this segment of the business aviation market, with companies announcing new projects, victories, and technologies. There were also major deliveries, such as the ACJ340 by Gore Design Completions, and projects coming down the pipeline (two Boeing 747-8 aircraft at Lufthansa Technik, for example). Suppliers are reporting a growing demand for their services, which means that in general the interior outfitting business is doing fine. Duncan “Today’s buyers are looking for a turn-key, ready-to-go, pedigreed aircraft with a current inspection status and a record of who performed the inspections. Although safety tends to trump cosmetics, buyers want an exterior that’s sharp looking and an interior that’s easy to personalize with very little downtime,” says Doug Roth, Aircraft Acquisition and Consignment Representative at Duncan Aviation.
The company, based in Lincoln, Nebraska, delivered several aircraft in 2013, including a refurbished Global Express and Falcon 900, as well as a Global 5000 with a memorable paint job. Customers are a mix of those who want to re-sell their aircraft or give it an overhaul and use it themselves. According to Duncan Aviation, the main areas to focus on apart from the actual leathers, veneers, and carpet are the cabin management system (CMS), lighting, and avionics. A Falcon 900 exhibited by the company at NBAA in Las Vegas last year demonstrated the entire range of capabilities of Duncan Aviation. A Universal Avionics cockpit upgrade centred on only the necessary instruments, maximizing efficiency. The exterior was re-painted and the aircraft got new winglets. Inside, it was completely refurbished, including new cabinets and tables, stone counters, drink rails, and more. The aircraft got EMTEQ LED mood lighting and a Rockwell Collins Venue CMS, resulting in a thoroughly modern cabin with all features one would expect of a Falcon 900 acquired today. The Duncan Aviation paint shop confirmed its expertise when the company delivered a unique Global 5000: OE-IXX, operated by Amira Air. The customer brought a paint scheme with curving lines entangling the fuselage to create a very intricate 3D image. “The first thing the sales staff asked us was, ‘can you do this?’” said Master Paint Specialist Stacy Finch, who has been with the company for 15 years. “Our immediate response was, ‘of course.’ We love a good challenge.” The job was so complex it had to be literally done by hand, taping each line on the fuselage to ensure it curved correctly. Thanks to the team’s experience, the resulting exterior is striking and memorable, as the customer undoubtedly intended. RUAG Aviation Another player making big strides in the refurb business is Oberpfaffenhofen-based RUAG Aviation. Before EBACE 2013 the company delivered its first full-cycle VIP completion of a CRJ200. As opposed to working with existing layouts or updating requested parts of the interior, as has been the case for previous projects,
this involved everything from planning out the layout to creating a tailored design for the components. Aided by partners from next-door 328 Design studio, RUAG created a ten-seat aircraft with an absolutely modern inflight entertainment system and a fully wireless CMS that can be controlled from tablets or smartphones, just as on the high-end business jets rolling off production lines today. “This project was a perfect match for us right from the beginning, and thanks to the right team spirit and our certified specialists, we have managed this conversion in a remarkably short down time and at a competitive price,” said Robin Freigang, RUAG Aviation’s Director Cabin Interior Program VIP & Executive Jets. The additional advantage for customers is RUAG’s expertise in maintenance, repair, and overhaul. A refurb can be timed to major scheduled maintenance times when the aircraft is on the ground anyway, thus saving the owner time and money. RUAG has another design partner that will surely bring in some unique projects over the years: BRABUS Private Aviation, the business aircraft interior studio established by the famous Mercedes-Benz tuning brand and offering the familiar supercar and luxury sedan ergonomics and lines for aircraft.
The Jumbo Difference In the VIP airliner business, the situation is different, although generally even in the most opulent designs customers opt for economy and green technologies as well as functionality and comfort, as we will see from comments received from designers later on. Big names, such as Hamburgbased Lufthansa Technik, are busy generating new business and keeping up with existing orders. It’s still hard to get a slot in one of the well-known completion centers, as their schedules are outlined for years to come. Currently in the works are two Boeing 747-8 aircraft, expected to be delivered in 2014. Boeing is also the source of the most promising completions platform yet, the 787, and Lufthansa Technik is talking with several of the 12 787 VIP customers based on their great experience with widebody airliners. BizJet International, the whollyowned subsidiary of Lufthansa Technik based in the U.S., this year delivered the first privately-owned BBJ to China. The market, which is seen by many in the business aviation industry as having the most potential for growth, got a truly modern aircraft with a contemporary interior and an advanced entertainment system, featuring full Apple mobile device integration.
ADVANCES
RUAG Aviation is making big strides in the refurb business. RUAG’s stone floor on a Bombardier Global Express (pictured).
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COMPLETION AND REFURBISHMENT health, environmental and – most importantly for use in aviation – fire protection qualities remain on the same high level. The big news from San Antonio in Texas, where Gore Design Completions are based, are first of all in the change of ownership, with Saudi Arabian MAZ Aviation stepping in to buy the completions center. Company officials state that the two MAZ widebody aircraft, which were under way at Gore at the time, had no effect on the decision. Mohammed Al Zeer, head of MAZ Aviation who holds a degree in mechanical engineering from the University of New Haven in Connecticut, stated the following reasons for buying the company “No. 1, Gore has probably some of the best people working in this industry. And the second reason is that San
The company is about to deliver two major projects, a BBJ2 for an undisclosed customer, and a one-of-a-kind modification of a Boeing 767, the 4FS/ER. This is a former 767-based USAF prototype of the discarded E-10 MC2A program, acquired by the Bahrain Royal Flight in 2009. Apart from managing projects on a large scale, Lufthansa Technik has also made a significant advance in the small details by creating a new varnish system, for which it submitted a patent application. Although the new product contains just 20 percent of solvent as opposed to 60 in conventional varnishes, all of its visual,
ACQUISITION
Gore Design (top) was recently acquired by MAZ Aviation. Meanwhile, Jet Aviation’s Timeless to Visionary concept continues to impress clients. 56 - BART: FEB - APR - 2014
Antonio is probably one of the most business-friendly environments that I’ve ever come across.” According to Al Zeer, Gore design will add 200-250 people to its 700-strong workforce in the next two years. Both Kathy Gore Walters and Jerry Gore will remain with Gore Design as consultants. Despite some turbulence, the completions center had major successes in 2013, such as the delivery of an ACJ340 for a head of state. The huge airliner is divided into several major areas, including a dining/conference room with a big TV screen, a private bedroom with a double bed, and a master bathroom with shower, featuring a combination of wood, stone, and
gold to create a solid, classic house feel. The corridor running on one side of the aircraft past the VIP section adds to the home-like atmosphere and ensures privacy. Several sections in the aircraft feature firstclass and business-class seats for accompanying officials and entourage. There is also a medical room at the aft of the aircraft. The passageway flaunts a screen dividing wall to the conference room with optional opaque or transparent glass for privacy at the click of a button. The renewed Gore Design Completions won two Boeing 787 contracts in late 2013, ensuring we will hear more about the company in the future. Associated Air Center One more company from Texas, Associated Air Center based at Dallas Love Field, announced two milestone widebody contracts for an Airbus ACJ330 and a Boeing 747-8. To prepare for these and future widebody projects, AAC has invested several million dollars in facility improvements including hangar expansions, tooling, and training for existing widebody aircraft, as well as future Boeing 777 and 787 machines that will be coming in for VIP completions. The company has already doubled its workforce over the last year to nearly 500 to be ready for the significant increase in work load. The ACC Design Center offers customers a first-hand experience that not many can duplicate: since 2012, the company has a Boeing BBJ mock-up that allows it to physically show clients what certain section of the aircraft will look like, way before the actual green aircraft arrives for outfitting. Possibly an even more important advantage of this are the much reduced completion times, as engineers and technicians can now preinstall the planned interior on the mock-up and essentially give the full cabin a test-ride in terms of component compatibility and ergonomics. As for current projects, AAC performed scheduled maintenance and made various cabin enhancements to a Boeing 757 belonging to a returning head of state from Latin America. “Having long-standing, repeat, Head of State customers is a testimonial that our VIP customers choose to continue their relationship with Associated Air Center, trusting the safety and comfort
of their passengers to our longtenured team of experienced, trained and dedicated engineers, technicians and craftsmen,” said Chris Schechter, Vice President & General Manager, Associated Air Center. Jet Aviation Another big name in VIP airliner completions, Jet Aviation, has directed its efforts at establishing and promoting a first-class in-house design team led by designer Elizabeth Harvey. The company made big news by introducing its Timeless to Visionary concept in a variety of media, including a video created by Advanced Computer Art and a printed book with rendered images and an explanation of the inspiration behind it. The concept is comprised of two different interior designs for an identical floor plan of a Boeing 787. One is classic and elegant, built on a contrast of dark veneers and vertical surfaces with cream and beige leathers and carpets. An atmosphere of traditionalism and tranquility is reinforced by strong straight lines, the abundance of regular shapes and straight angles, as well as more subtle details such as the wooden sliding door of the TV cabinet and even an imitation fireplace. The latter would basically be a video screen, as a proper electric fireplace is unfeasible due to fire haz-
ard considerations. Other than that, both interior packages can be installed on a plane just the way they look, with seemingly free-standing furniture and the nice decorations that may be unnecessary in terms of function, but definitely add to the aesthetic appeal. Compared to the above Timeless design, the Visionary is bold, modern, hi-tech, but not to the point of lacking elegance. Simple lines combine with asymmetric shapes of contrasting colours in a white-grey-silver palette, creating a very bright environment reminiscent of modern designer homes. The window-shaped lights in sidewalls stand out as a particularly nice touch. Both the Timeless and Visionary concepts can be scaled to different aircraft and augmented with additional details, but mainly they exist to make a statement of the Jet Aviation Design Studio capabilities. And they have been making news around the world, in particular when the studio received the prestigious Society of British and International Design Award in late 2013. Design Celebrities Despite completion centers gaining expertise and customer trust in bespoke design, the top names in creating unforgettable aircraft interiors are as busy as ever, working mainly on airliners size ACJ/BBJ and up. Andrew Winch Designs have recently delivered a private ACJ319 modeled after a “Gentleman’s Club” concept. The studio strives to make each project unique, even when it is delivering a property, yacht, and aircraft for the same customer. According to Andrew Winch, tastes are very personal and are hard to categorize by region or nationality. “People are travelling around the world and meeting friends everywhere. One day they are at the opera in Vienna, the next they are in a restaurant in France. Then you meet them at a fashion show in New York. They are in a sort of club of its own, and if anything, there is an international standard of taste. Although, of course, there may be a heritage of taste for certain regions, influenced by local religion and art, but we find that every customer is different and comes to us because we are known to create unique designs of high quality,” he says.
PERSONAL
Andrew Winch, of Andrew Winch Designs says that his focus is on catering for personalized tastes.
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COMPLETION AND REFURBISHMENT Another major business jet interior components supplier Yankee Pacific Aerospace based in Rye, New Hampshire, has changed name to Advent Aerospace on 1 January 2014 to reflect a global reach of the company and its emphasis on technology, innovation, and product development. According to Managing Director Ken Goldsmith, the company is “doing really well this year. We’ve seen an uptick, largely driven by the advent of the executive 747-8 and we see the future further driven by executive variants of the 787, still to come are the business and private versions of the Boeing 737 Max and the follow-on 777X.” The company supplies galleys, cabinetry, bar units, crew rests, and up to entire cabins for single and
Tim Callies, known among other projects for designing the A340 for the German Government, agrees that due to globalization customers have a certain universal understanding of interior design, but can draw cultural parallels: “Each culture has its own individual taste, and for that reason I can`t say in general that there is at the moment a certain trend in materials and shapes in the aviation industry. Sometimes a customer from an older generation surprises me with his wish to have a contemporary, modern cabin design, while a young customer wishes to have a very classical design. Of course I can recognize different styles between the Arabic, Eastern Europe, and Asian cultures. “As in the fashion industry, certain design styles from the past become modern again from time to time. In the past few years I recognized that the ‘Art Deco’ style with its nice furniture details and beautiful materials like Makassar wood veneer and wonderful decorated fabrics were trendy in Eastern Europe, but also in some Arabic regions.” As for the state of the completions industry, Jacques Pierrejean sums it up for himself in a few sentences that may be true for others “On my side, I feel a quiet period for the middle market such as Falcon, Global Express, ACJ, BBJ aircraft. Most demand seems to be coming from Russia and Turkey. Asia is also very promising. Customers seem to be looking for unique designs and products, such as the Boeing 747-8 of our design that is currently in the works and scheduled for delivery in 2014.”
METICULOUS
Both Jet Aviation (top) and Lufthansa Technik (center) pride themselves on attention to detail.
Attention to Detail Things have also been happening on a smaller scale in the sector of business dedicated to supplying necessary parts and technology for larger operations, as well as updating certain structural components of aircraft. For example, Lou Martin & Associates, neighbors of Gore Design, and their sister facility Technical Composites Corporation have been busy designing shades, bulkhead partitions, and shell kits for helicopters and business jets, as well as refurbishing preowned machines.
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The breakthrough product for Lou Martin is the E3 shade, developed together with InspecTech Aero Service. Basically, the shade combines electromechanical parts such as a pleated shade with InspecTech’s SPD-Smart iShade electrochromic window. The passenger can choose between keeping just the pleated shade down to let in some light and warmth from the outside to completely blocking out the sunlight by fully dimming the window itself.
double aisle VIP aircraft. Subsidiary Jormac Aerospace specializes in headliner, bin, and sidewall systems for the Boeing BBJ/737/727/757 aircraft that optimize weight, acoustic isolation and ECS noise reduction, while providing complete installation hardware kits to meet the unique needs of each completion center.
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