Leeham News and Analysis
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Leeham News and Analysis
- Bjorn’s Corner: Air Transport’s route to 2050. Part 24. May 30, 2025
- Does an A220-500 need a new wing and engines? Part 3. May 29, 2025
- Boeing’s future depends on FAA approvals May 26, 2025
- Updated, May 29, 2025: Department of Justice, Boeing OK to Non-Prosecution Agreement May 23, 2025
- Bjorn’s Corner: Air Transport’s route to 2050. Part 23. May 23, 2025
Does an A220-500 need a new wing and engines? Part 3.
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By Bjorn Fehrm
May 29, 2025, © Leeham News: We are writing an article series about stretching the A220 to a capacity in the A320neo range. The idea is to replace the A320neo over time to make room in the A320/321 production lines for more A321s and extend the A220 family with a larger variant.
We analyzed what we need to change to bring the capacity to the level of the A320neo. We could achieve this with a fuselage stretch, but then the Maximum TakeOff Weight (MTOW) would need to increase to keep the A220 range. The wing and engines would then have problems, the takeoff run would get longer, and the climb to an efficient initial cruise altitude would be affected.
We now examine the potential fixes for these problems.
Figure 1. A rendering of an A220-500. Source: Leeham Co.
Summary:
- The A220-300 wing is not highly loaded compared to other Airbus single-aisle aircraft. With some modifications, it should be sufficient for an A220-500.
- The A220 engine is the mid-sized Pratt & Whitney geared turbofan, the PW1500G. It has limited thrust stretch capability. An alternative for a long-range (and thus heavier) A220-500 would be the CFM LEAP-1B from the 737 MAX.
Boeing’s future depends on FAA approvals
By Scott Hamilton
Analysis
May 26, 2025, © Leeham News: Boeing’s future depends on satisfying the Federal Aviation Administration (FAA) that its failures to follow safety protocols and quality control standards are behind it.
It’s been a rough six years since the worldwide Boeing 737 MAX fleet was grounded for 21 months following two fatal accidents five months apart. The existential threat to Boeing from the grounding was exacerbated by the two-year COVID-19 pandemic and a 20-month suspension in deliveries of the Boeing 787 due to production defects.
Then, just when Boeing was making progress, a previously undetected quality “escape” allowed a door plug on a brand new 737-9 MAX operated by Alaska Airlines to separate from the airplane at 14,800 ft shortly after take-off from Portland (OR) on Jan. 5, 2024.
A new crisis hit Boeing. The FAA, which had clamped down on Boeing’s 737 production line following the grounding on March 13, 2019, tightened its grip even further.
Today, Boeing is slowly clawing its way back.
In a media briefing last week for its fourth annual release of its Chief Aerospace Safety Officer Report (CASO Report), Don Ruhmann, the CASO, and three colleagues outlined Boeing’s progress in satisfying the FAA that Boeing is on a path to technical and safety recovery. (Financial recovery is not strictly the FAA’s concern and wasn’t covered in the briefing.)
Summary
- Boeing’s Speak Up program for employees did not have an independent manager to whom complaints, concerns, and suggestions could be tendered. Previously, line managers received complaints, raising fears among employees that retaliation was possible. Now, an independent manager is part of the process.
- Boeing told LNA that Ruhmann welcomes a meeting with the engineers’ union, SPEEA, to hear concerns over a stalled SPEEA safety initiative called ASAP.
- Preparations for expansion of 737 production to the Everett (WA) widebody factory are underway, but this, too, depends on the FAA.
The annual report is an outgrowth of the 2018-2019 737 MAX crashes and the crisis that followed.
Services are driving revenues and profits in difficult times, Part II
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By Karl Sinclair
May 22, 2025, © Leeham News: In our first look at OEMs in the aviation industry with a significant revenue stream derived from services, LNA analyzed airframe-makers.
Related Article
Now the focus shifts to engine and simulator manufacturers, and how after-market sales can pull a company through difficult times. It can even be the model, that a business follows.
FAA’s data of accident, incidents, often not shared
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By Colleen Mondor
May 19, 2025, © Leeham News: On March 27, acting FAA Administrator Chris Rocheleau testified before the US Senate Commerce Committee on the continued fallout from the Jan. 29 midair collision near Reagan National Airport in Washington (DC) between an American Eagle Airlines CRJ-700 and a US Army helicopter. All aboard both craft died.
In response to repeated questions from several senators about how warning signs about the congested airspace were missed, Rocheleau admitted that the agency needed to be more proactive about future safety issues, saying, “We have to identify trends, we have to get smarter about how we use data, and when we put corrective actions in place, we must execute them.”
FAA history of trend analysis
The FAA has collected safety information on National Airspace System users for decades. While the earliest data contained incident and accident reports drawn from the National Transportation Safety Board (NTSB), the agency’s Aviation Incident Data System and the Service Difficulty Reporting System were created in 1978. By the early 1980s, they were stored in the FAA’s “System 2000,” where eventually they were converted into usable formats and transmitted to FAA employees. It was cumbersome, time-consuming, and not entirely accessible. But it was a start, and by 1988, as listed in the following table from the Office of Technology Assessment, several other databases had been established.
| Data Type | Database | Federal Agency | Earliest Year* |
| Accident/Incident | Aviation Accident Data System | NTSB | 1962 |
| Accident/Incident | Accident Incident Data System | FAA | 1978 |
| Incident | Aviation Safety Reporting System | NASA | 1975 |
| Incident | Near Midair Collision Database | FAA | 1980 |
| Incident | Operational Error Database | FAA | 1985 |
| Incident | Pilot Deviation Database | FAA | 1985 |
| Mechanical Reliability | Service Difficulty Reporting System | FAA | 1978 |
| Air Operator Data System | FAA | 1980 | |
| Traffic Levels | Air Traffic Activity Database | FAA | Previous 18 months |
| Operational Practices | Air Operator Data System | FAA | 1980 |
| Air Carrier Statistics Database | RSPA | 1968 | |
| Inspection Results | Work Program Management System | FAA | 1987 |
| Violations/Enforcement Actions | Enforcement Information System | FAA | 1963 |
*Earliest year for data stored electronically. RSPA = Research and Special Programs Administration. “Incident” in this database does not always refer to NTSB-determined incidents. Other agencies sometimes use the term for any manner of non-accident events.
Services are driving revenues and profits in difficult times, Part I
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By Karl Sinclair
May 15, 2025, © Leeham News: The aerospace industry is a maintenance-intensive operation, where strict regulatory rules drive many requirements.
Assets must be constantly maintained, governed by the time or usage an airline derives from them.
This goes for airframes, engines, and human resources.
Services account for a large part of aerospace corporate profits. Boeing’s Global Services division is the most profitable part of the company. Photo credit: Boeing Global Services.
Some equipment manufacturers derive little or no profits from product sales, but they make lucrative and long-term revenues from attached maintenance contracts.
Political factors are also coming into play in the services segment.
As airlines are forced into a difficult and expensive decision regarding the payment of tariffs on new aircraft they acquire, many could opt for a different strategy.
Older aircraft that were due for replacement with newer, more fuel-efficient jets will be sent into MRO facilities for an additional heavy-maintenance check.
With falling fuel prices playing less of a factor in the acquisition decision, airlines will be tempted to defer deliveries (thus avoiding the payment of tariffs) using their current assets in their installed fleets.
Extending an aircraft’s useful life by another six to seven years will allow carriers to simply wait out the tariff threat when things return to normal.
LNA looks into the growing services revenue segment among various companies in the aviation industry.
The BWB has a long way to go before flying passengers, freight
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By Scott Hamilton
Figure 1. The Horten flying wing developed by the Germans toward the end of World War II. Credit: Michael Jorgensen via BBC.
May 12, 2025, © Leeham News: The Blended Wing Body airplane concept has been around for decades. Its cousins, if you will, appeared in the form of flying wings. The Germans developed the Horten at the end of World War II; it never made it into service.
Northrop Grumman developed propeller- and jet-powered flying wings after World War II. Neither concept was picked up by the US Air Force.
Figure 2. The Northrop YB-49 flying wing developed post-World War II. Credit: Northrop.
It wasn’t until development of the Northrop Grumman B-2 bomber that the flhing wing, or Blended Wing Body, aircraft became an operational reality.
Figure 3. Northrop Grumman B-2 bomber. The similarities with the JetZero Z4 BWB are apparent. Credit: Northrop Grumman.
But none has been able to make the leap into commercial aviation service. JetZero hopes to make this leap in the early 2030s, but it’s got a lot to accomplish between now and then.
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JetZero readies effort for private equity funding
Many of these challenges were outlined by LNA last week. But there are more.
Does an A220-500 need a new wing and engines? Part 2.
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By Bjorn Fehrm
May 5, 2025, © Leeham News: We started the articles series about stretching the A220 to a capacity in the A320neo range last week by going through the development of the A220-100 and -300, how it’s designed and compares to the competition in the 100 to 140 seat segment.
Now, we analyze what we need to change to bring the capacity to the level of the A320neo and whether changes to the wing and engines, in addition to prolonging the fuselage, are necessary when we increase its capacity.
We use the Leeham Aircraft Performance and Cost Model (APCM) to look at the design data for the A220-300 and discuss what it will mean to make the different changes.
Figure 1. A rendering of an A220-500. Source: Leeham Co.
Summary:
- The A220-300 has field and range performance that matches an A320neo.
- As we increase the length of the A220 fuselage to match the seating capacity of the A320neo, we run into tricky trade situations regarding range and field performance for an A220-500.
JetZero readies effort for private equity fund raising
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By Scott Hamilton
May 5, 2025, © Leeham News: JetZero, the start-up company developing commercial aviation’s first passenger Blended Wing Body (BWB) airplane, is gearing up to seek private equity funding for billions of dollars needed to bring its aircraft to market.
JetZero president and COO Dan da Silva demonstrates the human scale of the Z4 Blended Wing Body mock-up at the company’s Long Beach (CA) facility. Credit: Leeham News.
In a media day on Friday, executives and staff briefed reporters on progress to date, production work on the first full-size demonstrator aircraft, technical details and studies continuing an production plans.
Officials expect to announce a site selection for its final assembly plant in the coming weeks, before the Paris Air Show that begins in mid-June.
JetZero’s airliner is dubbed the Z4. It’s nominally a 250-passenger, 5,000nm design for the so-called Middle of the Market currently occupied by out-of-production and aging Boeing 767-300ERs, Airbus A330-200s and a limited number of Boeing 757s. Entry-into-service is targeted for the “early 2030s.” The first flight of the demonstrator aircraft is planned for 2027.
JetZero has an ambitious goal for producing the composite aircraft. The final assembly site, for which the company has down-selected the finalists, will be on a 1,000 acre site with a building about the size of Boeing’s widebody plant in Everett (WA). Boeing’s Everett site is somewhat larger than 1,000 acres.
JetZero is planning for a monthly production rate of 20 five years after production begins. The company has hundreds of conditional orders from major airlines.
Daunting tasks remain in the coming years. Among them: there is currently no engine commitment for the airplane; a product support system is needed; finalizing the method to product the composite airplane; “flying” the iron bird; and much more.
Does an Airbus A220-500 need a new wing and engines?
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By Bjorn Fehrm
May 1, 2025, © Leeham News: For years, the debate has been going on about when Airbus will complement the A220-100 and -300 with a longer, higher-capacity A220-500.
In fact, the Bombardier team that designed the A220 as the CS300 already foresaw the prospect of a longer -500. The latest discussions have been around how much to stretch and whether a new wing and stronger engines are needed if the A220-500 replaces the A320neo in the Airbus lineup.
We use the Leeham Aircraft Performance and Cost Model (APCM) to examine the design data for the A220-100 and -300 and determine whether a stretched -500 would benefit from a new wing and stronger engines (which would then be the CFM LEAP-1Bs used on the Boeing 737 MAX).
Figure 1. A rendering of a possible A220-500. Source: Leeham Co.
Summary:
- The A220 started life as the CSeries, designed to compete with Embraer’s E-Jet E2.
- It has since added range through increased Maximum Takeoff Weights to enter the single aisle segment range-wise.
- A stretched A220 would expand the present A220 series upwards and potentially replace the A320neo for Airbus.
- We start by comparing the A220 to the E2, then we move on to examining whether an A220-500 can successfully replace the A320neo.
Boeing wants to remarket China’s airplanes. It’s costly and time consuming.
- China has 130 Boeing airplanes that are identified in the Boeing backlog. On last week’s earnings call, officials said China accounts for 10% of its backlog of 6,319 aircraft as of March 31. This means there are about 500 Chinese-destined aircraft in the “Unidentified” backlog.
- Reconfiguring airplanes would cost millions of dollars. Backlogs to order materials and complete the work could be as much as two years. Engineering that may be required and regulatory review also could take a year or two.
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By Scott Hamilton
Reconfiguring aircraft interiors is a costly and time-consuming challenge. Aftermarket company ATS is one of those engaged in this sector. It explains the process here. Credit: ATS.
April 28, 2025, © Leeham News: China used to be Boeing’s most important single collective customer. By the end of 2016, this country’s airlines and lessors accounted for between 25% and 33% of Boeing’s annual deliveries, depending on the year.
Boeing was losing ground to Airbus there. The European rival aggressively sought to partner with China. In 2008, the company opened an A320 family final assembly line in Tianjin. This followed a long courtship in which Airbus boosted its supply chain and engineering in China. Airbus establishing an A330 finishing center in China in 2017.
In China, doing business there meant providing “benefit” to its new and growing industries. “Benefit” was a loosely defined term that generally meant transferring technology, helping create a supply chain and ordering parts and components made in China. For some, it meant providing kickbacks. (This is not suggesting Airbus engaged in kickbacks, but corruption is a matter of public record. Such was suggested to me when I was doing business in China between 1989 and 1993.)
It had been a long struggle. When Airbus was establishing its presence there selling airplanes, some officials said they didn’t need any air buses—passengers boarded by jet bridges. Over time, Airbus began to surpass Boeing’s orders in China and today is the leader.
Boeing recognized it needed to do more in China. It floated the idea of establishing a 737 final assembly line in China, but its touch-labor union, the IAM 751 exercised its veto contract clause to stop the idea. Instead, Boeing opened a 737 completion center in China in 2018.
Completion centers paint the airplanes and install the interiors. A few 737s were at Boeing’s completion center when President Trump started the tariff war with China; the airplanes returned to the United States.