Increasing numbers of airlines and business jet operators around the world are investing in refurbished, refreshed cabins with the latest technology. Inflight Editor Satu Dahl speaks with different companies working on these impressive cabin refurbishment projects to learn how they have evolved according to market needs and what trends they are seeing in the future.
This article was originally published in the September/October 2024 edition of Inflight. To receive articles and news directly to your inbox, apply for your complimentary subscription to Inflight.
Soisa Aircraft Interiors – Innovators in the cabin refurbishment industry
Technological advancements, exciting new materials and innovative new products ensure that there is always a plentiful supply of exciting features for aircraft operators to integrate in their cabin refurbishment projects.
Speaking with Soisa Aircraft Interiors’ CEO Jacobo Mesta, it is evident that the company keeps its offering on top form.
Just some of its latest innovative developments include a revolutionary organic armrest made of a base of corn particles, which contributes to carriers’ sustainability efforts, as well as its buyer-furnished equipment (BFE) dress cover management service, resulting in cost savings and reduced lead times.
Soisa Aircraft Interiors has expanded into new markets and territories over the years and saw the opportunity of near shoring in the UAE because a big part of the aerospace market is based there.
Mesta tells Inflight: “We started a business plan in order to get established next to one of the largest airlines in the world in the UAE, and from there capture the North American, European and Southeast Asia markets.”
The company opened its new facility in Dubai in October 2022. “We are always trying to search for opportunities to be as close as possible to our clients so we can reduce their cost and lead times, speeding their interior products to market.”
Soisa Aircraft Interiors has a fascinating history, as Mesta recounts.
“My grandfather started an upholstery business in 1949 – ‘Fabrica de Ropa Diamante’. So the family has been in the upholstery business of cut and sew since 1949, where we manufactured jeans for Billy the Kid in the USA, but we also exported to Europe.”
Mesta says the company also manufactured sports clothing for the Champion sporting brand in the USA, but in 2000 when the Chinese came to Mexico with no tax on the denim and with very cheap jeans, it went completely bankrupt.
“That was when we had to close the factory and sadly let go more than 2,000 people,” he recalls.
At around the same time, however, Zodiac had arrived in Chihuahua with one of their first facilities.
“So my father and his brother started searching for opportunities in upholstery and export, which was our expertise,” says Mesta.
“In 2004, aerospace came big to Chihuahua and since we always participated in the Boards of Economic Development and the Chambers, it was well known that we were in the upholstery business in Chihuahua.”
” We are always trying to search for opportunities to be as close as possible to our clients so we can reduce their cost and lead times, speeding their interior products to market. ”
Jacob Mesta, Soisa Aircraft Interior’s CEO
Going global – Evaluating the future of the cabin refurbishment industry
Today, Soisa Aircraft Interiors’ laminated dress covers are by far the most popular products among airlines, Mesta says.
“Our lamination is used by the most prestigious airlines such as Emirates, AA, United, Etihad, China Eastern and Singapore Airlines, among many others.
“By being able to use different types of lamination, and to duplicate the process in Dubai, the great relationship we have with all the material vendors in order to be able to use many different products to get the aesthetic and quality that the airlines like has been a big help for Soisa.”
When it comes to Soisa Aircraft Interiors, it is evident that the company has worked very hard to be where it is today. But how does Mesta see the market, as well as the company, evolving in the future?
“We are very happy and hopeful with this big increase that we are having in the industry, so we are preparing for it,” he says.
“We see the OEMs increasing their production and also a lot of airlines doing retrofit programmes on their seats, so this is very important for Soisa Aircraft Interiors.
“Also, we just started a huge lean manufacturing process in Soisa called ‘SOILEAN’. With this we expect to increase our capacity by 30 per cent in the production side among many other benefits that we will have.
“This will allow us to speed to market the OEMs’ and airlines’ interior products, reducing cost and lead times.”
Lighting up the interiors – The sparking demand for lighting and connectivity
New and improving technologies are very much part of cabin refurbishment programmes.
IFPL has been leading in the IFEC peripherals industry for ver 25 years. Image; IFPL
IFPL Group companies IFPL and Cobalt Aerospace’s products include entertainment, power, connectivity, lighting and safety solutions for aircraft.
It has worked on large-scale refit projects, and this year a huge highlight was collaborating in Bulgaria with some of the world’s leading suppliers on the Electra Airways refit.
A spokesperson says: “Getting to witness Electra expanding their fleet and having a behind-the-scenes pass to see the work undertaken during a retrofit programme and getting up close and personal with the new product ranges selected by Airbus design studio was a great opportunity.
“Not to mention seeing our Cobalt Spectrum 2 lighting being installed so quickly by the ETG maintenance team and being able to showcase our unique Northern lights sequence for all the team.”
Having an access-all-areas pass with the Vector group to film the full cabin refresh has enabled the company to demonstrate the ease and speed with which its Spectrum lighting can be installed.
“We were able to speak directly to the ETG team completing the installation and gain their raw feedback. Seeing the full complement of suppliers come together and make a 20-year-old aircraft look like new was an opportunity we could not miss.”
When it comes to solutions that IFPL considers to be in high demand for cabin refurbishments, it sees USB-C Power Delivery as essential.
“Passengers want to charge all their devices, including laptops, which require more power than standard USB ports provide. These high-power ports are becoming fundamental as more devices adopt USB-C PD standards.”
Durability and reliability are important to ensure passengers avoid battery anxiety and always have accessibility to power.
“Our patented cartridge technology supports airlines with low maintenance costs and is quick to install should customer-induced damage (CID) occur. Providing power to passengers irrespective of their flight duration is becoming a real differentiator between airlines when people are selecting a carrier for their flight.”
Patent pending – IFPL’s understanding of the IFEC technology industry
IFPL understands the speed of technological developments and provides solutions that keep up with that evolution.
“We have a new patent pending for our Flex power system that is truly game-changing. It will give airlines more choice as to the power level offered to passengers, and is built to be fit for the future with its peer-to-peer wireless communication, enabling every seat to offer up to 60W USB-C-PD. It is fully reconfigurable, with the ability to easily switch from USB-A to C when the market requires.”
When asked about a solution that is becoming a must-have for airlines, IFPL says it has to be easy to use, programmable mood-enhancing LED lighting.
“With the backlog on new aircraft and delivery dates getting longer, operators are having to consider an alternative route to growing their fleet and keeping their existing aircraft looking new. With many airlines wet-leasing aircraft, there comes the desire to have a simple system to operate that is easily adaptable to the leased airline’s brand colour.
“Our Spectrum 2 lighting with its optional wireless controller gives a simplistic set-up allowing up to 16 dynamic lighting scenarios at the push of a button, with minimal interaction with the flight attendant panel.
“For rebrands, end-of-lease and special celebrations we have a simple fast-track route for colour scene changes controlled by our in-house DOA.”
In addition to lighting, the company seeing the growing trend of passengers wanting to use their own device on flights and ensure they can charge that device.
“Much of this is driven by the increase in aircraft connectivity and expansion of retail and entertainment offerings across many narrowbody fleets that in the past had nothing. This means operators are looking for power solutions up to 60W.
“Our Flex offering goes a step further and allows the airline to control the number of available outlets, the power level the passenger has and can have several combinations of USB ports with our patented cartridge technology.”
Inviting interiors – Winch Design’s contributions to the aircraft interiors industry
Design studios are of course integral to aircraft cabin refurbishment projects.
On the business aviation side of the industry, design studio Winch Design recently completed an extensive Bombardier Global 6000 refurbishment project, transforming a 10-year-old business jet into a unique contemporary masterpiece inside and out.
Winch Design, which was founded in 1986 by Andrew Winch and his wife Jane, now comprises more than 150 talented individuals.
In July 2021, Winch Design became fully employee-owned, further enhancing its innovative and entrepreneurial culture.
The client brief for the Bombardier Global 6000 was to create an inviting, relaxed interior which wouldn’t feel like you were on an aircraft and that had the durability to withstand a busy charter schedule.
Jim Dixon, Managing Partner & Creative Director at Winch Design, says: “The design process took six months, with the refit taking just over a year to complete. In this time the aircraft was only out of action for three months.”
Exterior design of the Bombardier Global 6000 project. Image; Winch Design
He adds that the refit for the cabin refurbishment took place alongside the extensive C Check following 10,000 hours of operation.
“During a C Check, the interior has to be stripped of furniture and carpeting so that inspectors can look for structural flaws in the fuselage and bulkheads, and the exterior paint job is removed for the same reasons. This made it the perfect time to upgrade the interior and exterior.”
The project was carried out at the Bombardier facility at London Biggin Hill Airport and the refurbished aircraft is now available for charter with Alliance Jet.
Attention to detail – Aircraft cabin interior features
“The striking exterior colour and contemporary graphic pattern were designed to be a stark contrast to the more traditional ‘sweep’ exteriors which dominate the runways,” Dixon says.
The graphic also extends to the inside of the winglets, allowing the design to be seen from the cabin and connecting the interior with the exterior.
The project was carried out at the Bombardier facility at London Biggin Hill Airport. Image; Winch Design
Dixon says that when it comes to the most innovative features of this design, the slatted bulkheads are something that has not been done on an aircraft before.
The 3D slatted screens are made up of light-coloured wood and mirrors to provide privacy and enhance the sense of space.
“The foil imitation of real wood which the cabinetry is wrapped in is also an innovative feature,” says Dixon. “This is a technology that has improved to the point where it looks and feels like authentic wood grain. This saved time, cost and weight, and the untrained eye can’t really tell the difference.”
The hand-tufted carpet is also pretty unique, with the wave-like pattern in bright aqua blue transitioning through subtle gradients inspired by natural textures and vibrant ocean colours.
Dixon says: “The carpet’s colours are reflected in the stitching on the leather inlays of the tables, while the wave-like pattern continues across the upper side walls and ceilings, adding depth and character to the space.”
The slatted bulkheads posed a challenge as they involved repositioning switches and exit signs and ensuring the internal valance panel was still able to hinge down for maintenance.
“The Bombardier team helped ensure we got all the correct certification required,” says Dixon. “One of the biggest hurdles to overcome was ensuring that the bulwark was not too heavy for certification.”
The aft veneer wall was another challenging aspect. The wall is a marquetry veneer pattern in walnut – the only piece of real wood added during the refit.
F/List developed an innovative oil finish that had to pass flammability testing and certify as a process, whilst still retaining a natural wood look.
Investing to expand – Starling’s interior refurbishments and investments
UK-based Starling Aerospace has seen significant growth in demand for bespoke aircraft interior refurbishment projects.
The company has extended its design and manufacturing capability thanks to a six-figure investment.
Starling’s Co-Founding Director, Coralie Wigg, tells Inflight: “This major investment in machinery represents the biggest upgrade in Starling’s capability since the company was established more than two decades ago.
“By combining different sewing tasks into a single CNC machine, we can create any design for leather and fabric, no matter how complex.
“Equally, our in-house autoclave provides an agile solution for customers needing a fast project turnaround.
“Starling is seeing a growing trend for completely bespoke interiors, so we are well positioned to deliver increasingly exotic designs that our clients are demanding.”
Aqua Transfer System. Image; Starling Aerospace
The company, which carries out all of its aircraft interior refurbishments engineering and certifications in-house at its facility in Leatherhead, Surrey, has further invested in a laminating machine for seamless bonding of leather to foam for aircraft seat refurbishment, together with an additional CNC machine to precisely cut aviation-grade metal billets to make high-quality components.
Recently, Starling designed, manufactured and certified a bespoke modular triple wardrobe stowage solution and an XXL changing room lavatory on a VVIP Airbus A321.
“This project was an engineering feat,” says Wigg, “as they certified the lavatory in a location on the aircraft where the OEM had never done so before.”
Some of Starling’s other recent projects include an entire cabin interior fit-out on a Cessna Citation CJ1, which was accomplished entirely in-house, as well as an ongoing VIP Airbus A330 project, performing aqua transfer printing on all the monuments within the aircraft.
The company says the challenge was to handle the large monuments, which it successfully overcame.
Interior features such as leather seat covers, aqua transfer system, carpets, veneer repairs and build-to-print services all see high demand in cabin refurbishment projects, Wigg confirms.
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