Leeham News and Analysis
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How’s the next new aircraft produced? Part 2. Advancing the State of the Art
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By the Leeham News Team
Sept. 8, 2025, © Leeham News: In the second part of our article series about the Production of the next new aircraft, we look at the latest trends around advancing the state of the art for aircraft production.
Figure 1. The next new airplane, whether from Airbus, Boeing, Embraer or another company, will use AI and other new technologies. Credit: Leeham Co.
Artificial Intelligence (AI) is going to replace human beings, or so claims Elon Musk.
Digital design and digital twin factories are going to dramatically lower costs, speed construction, and improve production efficiency. At least that’s what proponents claim.
While there might be a lot of truth in these claims, it’s not the whole story.
But the drive toward reindustrialization, as one industry consultant calls it, may be a drive that is too theoretical and could overlook the fact that production is done and controlled by humans.
One aerospace company is putting the brakes on the theoretical spin and focusing on the road to higher efficiency by slowing down this transformation in favor of employee training and motivation to emphasize safety over cost-cutting and automation to gain efficiency.
Striking a balance between the reindustrialization theoretical gains and the focus on the human in the system will be tricky. LNA had spent months interviewing companies, consultants, current and former employees of key companies, and researching public-domain information to paint a picture of how production will be transformed in the coming years.
We begin the advancement of the state-of-the-art part of the series with an interview LNA did at the Paris Air Show with the consulting firm Accenture.
How’s the next new aircraft produced? Part 1. The starting point.
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By the Leeham News Team
Sept. 4, 2025, © Leeham News: The coming decade is likely to see announcements of new airplanes from Airbus and Boeing. If Embraer decides to move up into the mainline sector, a new airplane from the Brazilian manufacturer should also be announced in the next few years.
This means the clock is ticking toward program launches anywhere between 2027 and 2030, depending on progress from GE Aerospace, Pratt & Whitney and Rolls-Royce in developing new engines.
New airplane concept: The Boeing New Midmarket Airplane, c. 2019. Credit: Leeham News.
For the airframe manufacturers, there are important steps before a new program can be launched. One is how the aircraft shall be developed. We wrote about it in our series “What’s the Next New Aircraft?”. But equally important is, how shall the next new aircraft be produced? It’s what this seven part series is about.
Since June, LNA has published a series of articles about new airplanes, new technologies, new design and new production processes that must be sorted before any of the OEMs move forward. Across the seven parts of this series, we identify flaws and challenges at both Airbus and Boeing, with lessons to be learned as both airframers reshape their approach for future manufacturing.
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We call this series “How’s the next new aircraft produced?”. We start by going through where the major OEMs are with their legacy production.
Trump tariffs beginning to hurt US aerospace companies; EU competitors to benefit
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By Scott Hamilton and Karl Sinclair
Sept. 1, 2025, © Leeham News: New policies by President Donald Trump in the first six months of his second administration in trade, with the North Atlantic Treaty Organization (NATO) and the European Union (EU) are causing a what may become a significant shift in defense spending that will benefit European companies.
The added business could strengthen those that also participate in commercial aerospace, to the detriment of US companies, notably Airbus.
US companies that for decades were the major suppliers to allies are already beginning to see European countries redirect spending to EU firms. Following Trump’s imposition of high tariffs on certain EU countries and others on Aug. 1, US defense companies have been hurt. India canceled deliveries of Boeing 737-based P-8A Poseidons.
Figure 1. Boeing P-8, based on the commercial 737 NG. India suspended delivery of the P8 due to the Trump tariffs. Credit: Boeing. Airbus now proposes a rival airplane based on the A321.
Airbus, Rolls-Royce, MTU, and others expect to benefit from these changes. And, as these companies see more defense work coming their way, then—at least in theory—their commercial business will benefit from stronger balance sheets, profits, cash flow, and perhaps the corporations’ technology.
In an interview at the Paris Air Show in June, the consulting firm Accenture told LNA that it is beginning to see key trends and increases in the defense sector.
Figure 2. Spain and Switzerland canceled orders for the Lockheed F-35. Credit: Lockheed. Airbus stands to benefit, among other EU-based defense contractors.
“Obviously, things are changing in terms of the dynamics,” said Jeff Wheless, Growth & Strategy Research Leader at Accenture. “I think certainly from a NATO perspective, I think folks are increasing their spending.”
Mark Rutte, the NATO secretary general, said that Trump’s pressure on NATO countries to increase defense spending to 5% of their budgets paid off. For decades, NATO countries were committed to a 2% spending level, but often failed to meet this commitment.
“Europe is spending by far less money on defense acquisitions than the US,” said Airbus CEO Guillaume Faury in response to an LNA question at the Paris Air Show. “It’s a ratio of one to four or one to five. On top of that, Europe is procuring a lot from the US. I think the message is loud and clear from the U.S. that Europe should take better care of its own security.”
Airbus’ A330neo gets better and better. Part 4
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By Bjorn Fehrm
August 28, 2025, © Leeham News: We analyze Airbus’s A330neo, how the different variants were developed, their sales, and their performance before and after the neo upgrade.
After examining the history of the A330-200 and its evolution into a neo version, the A330-800, we now assess its performance. We utilize our Aircraft Performance and Cost Model (APCM) to compare the performance of the A330-800 to Boeing’s smallest Dreamliner, the 787-8.
Figure 1. The A330-800, the very long-range A330. Source: Airbus.
Summary:
- The Airbus A330-800 is an aircraft for especially demanding routes. It’s the only 8,000nm airliner in the 250-seat class.
- Our 787-8 comparison shows where the A330-800 has its advantage, on the world’s longest routes.
GE increasing use of automation and AI to support MRO
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By Scott Hamilton
A tool used by GE Aerospace for its Artificial Intelligence MRO process. Credit: AIN.
Aug. 25, 2025, © Leeham News: GE Aerospace is using robotics, automation, and Artificial Intelligence (AI) as well as rare access to supercomputers throughout its global footprint, services, and in research and development as it strives for engine maturity, reliability, and creating new engines.
Shop visits, on-wing engine inspections, and repair technologies must be made more efficient, rapid, and cost-effective to serve the thousands of legacy CFM56s, GE90s, CF6s, and the growing number of CFM LEAP engines.
The CFM56 and LEAP engines power the Boeing 737. The CFM 56 and LEAP also power the Airbus A320neo family in competition with the previous generation International Aero Engine V2500 and the current generation Pratt & Whitney GTF, respectively. The CF6 still powers older widebody airplanes, like the Boeing 767. The GE90 powers legacy Boeing 777s.
The forthcoming GE9X, the giant engine on Boeing’s 777X series, is also benefiting from efforts to mature the engine as much as possible before entry into service next year. This is a special case because of the six-year certification and delivery delays of the 777X brought by some initial technical issues of the GE9X discovered during flight testing and the negative halo effect of the certification crisis surrounding the 737 MAX, beginning in 2019.
The 777X was to be delivered in the first quarter of 2019; now, entry into service (EIS) is expected next year.
Related Article
Airbus’ A330neo gets better and better. Part 3
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By Bjorn Fehrm
August 21, 2025, © Leeham News: We analyzed Airbus’s A330-300 and -900 over the last weeks, the mid-range Airbus that gradually developed into a credible long-range aircraft.
After examining the A330-300’s development into the A330-900, we now analyze the A330-200 and its neo version, the A330-800. Why was a shorter A330-200 developed and put into service four years after the A330-300, when in almost all other cases the next version is a stretch?
And why did this smaller A330 sell really well against the larger A330-300 when its neo version doesn’t? We utilize our Aircraft Performance and Cost Model (APCM) to analyze the A330-200 and -800. Then we compare the A330-800’s capabilities and efficiency with Boeing’s 787-8.
Figure 1. The A330-200, a model that sold almost half of all A330s until the A330neo was announced. Source: Airbus.
Summary:
- The Airbus A330-200 was one of the airline world’s few successful shrinks from a base version. Normally, base versions get complemented with higher capacity versions, and shrinks are duds.
- The A330-200 and now the A330-800 compete with Boeing’s 787-8. How do these compare?
P&W pursues “Industrial 4.0” with GTF engine improvements
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By Scott Hamilton
Aug. 18, 2025, © Leeham News: Pratt & Whitney’s long slog in fixing one technical problem after another with its marque PurePower Geared Turbo Fan engine isn’t over yet. It won’t be for another couple of years.
But during the Paris Air Show in June, those LNA talked to were optimistic that the end of the problems is in sight. And they are surprising optimistic about how well PW managed through the crisis and prospects for the future.
Top people at two firms that advise airlines and lessors on engine selection and maintenance contracts told LNA that for all the grief the GTF caused over the years, including hundreds of Airbus and Embraer aircraft grounded while awaiting new engines, PW gained a lot of traction by working with customers to mitigate revenue and cost losses.
That’s not to say that all are satisfied with PW’s response to the years-long series of disruptions. However, one advisory firm leader told LNA that PW’s Advantage GTF (the latest, advanced version, not yet entering service) will have airlines “flocking” back to PW if the engine performs as advertised.
The Advantage GTF will have 3%-4% more thrust and better fuel economy than the preceding GTF engines. Advanced materials, powders, and parts are expected to be more durable than those used in previous engines.
A revealing side note: these same advisors criticized the response from GE Aerospace for being less than cooperative and for not providing enough mitigation responses to shorter on-wing times for the CFM LEAP engine.
Pratt & Whitney’s Asheville (NC) “Industrial 4.0” plant aims to capitalize on digital, advanced manufacturing. Credit: Pratt & Whitney.
PW also has spent more than $1bn on what it calls an industry 4.0 production plant in Asheville (NC).
Airbus’ A330neo gets better and better. Part 2
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By Bjorn Fehrm
August 14, 2025, © Leeham News: We analyze Airbus’s A330-900, the larger of the A330neos. Last week, we examined the product improvements that Airbus will roll out in the coming years, including the latest increase in Maximum TakeOff Weight (MTOW) and the resulting increase in range.
The A330 entered the market as a mid-range aircraft. With the launch of the A330neo and subsequent improvements, it is today a long-range aircraft that covers several trans-Pacific trunk routes.
How does the improved A330-900 stack up against the efficiency of the Boeing 787-9? We use our Aircraft Performance and Cost Model (APCM) to find out.
Figure 1. The A330-900 in the colors of Delta Airlines, a major operator of the model. Source: Airbus.
Summary:
- The Airbus A330 is tested on a challenging route, LAX to Shanghai, versus Boeing’s perhaps best long-ranger, the 787-9.
- Where Airbus can’t match the efficiency and cargo capacity of a 20-year younger 787-9, it can compensate with lower capital costs.
Collins Aerospace continues R&D on electrical options despite industry pullback
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By Scott Hamilton
Aug. 11, 2025, © Leeham News: At the Annual General Meeting of the International Air Transport Association (IATA) in October 2021, a detailed green aviation plan was adopted to achieve net-zero carbon emissions by 2050.
The ambitious program included milestones in the use of Sustainable Aviation Fuel (SAF) and other alternative fuels. The policy was part of a greater industry effort to develop battery, hydrogen, and hybrid-powered aircraft and eVTOLs.
Some 300 companies were founded to pursue these various objectives, and many global airlines adopted environmental goals. Some placed conditional orders for eVTOLS or hybrid aircraft.
Boeing focused on SAF development while Airbus pursued hydrogen-powered concepts. GE, Safran, Pratt & Whitney, Pratt & Whitney Canada (PWC), and Rolls-Royce each have or continue to research hybrid or new engine opportunities.
Todd Spierling of Collins Aerospace. Credit: Collins Aerospace.
Plenty of skepticism about reaching the Net Zero goal emerged even at the 2021 IATA AGM. Tim Clark, president of Emirates Airline, famously cautioned, Don’t make promises you can’t keep.
Since then, Airbus abandoned its hydrogen goal. Several airlines abandoned their net-zero goals. Most of the 300 start-up companies failed, notably Lilium, which went through an astonishing $1bn before collapsing into insolvency.
One company that acknowledged the idea that aircraft can be powered by batteries alone is Collins Aerospace, a unit of RTX Corp. In an interview with LNA before the Paris Air Show, Todd Spierling, a principal technical fellow, was clear.
“We’ve been working a lot with Pratt and Whitney on electrification and what it means,” Spierling said. “One of the things we found was if you just trade out fuel for batteries, it doesn’t work out.”
Airbus’ A330neo gets better and better
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By Bjorn Fehrm
August 7, 2025, © Leeham News: Airbus’ A330neo, as the A330-900, entered the market in 2018. It’s a major improvement of the A330ceo that entered the market in 1994 as a 270-seat 3,900nm mid-range aircraft.
The present A330-900 has gradually improved its sales, prompting Airbus to increase the production rate from the planned four per month to five from 2029.
With a typical 290-seat cabin, Airbus advertises a 7,300nm range for the 251t Maximum TakeOff Weight (MTOW) version, quite a development from the original 212t A330-300. And now this is going to improve further from 2028, with a rise in the MTOW from 251t to 253t, together with other improvements.
Does this make the A330-900 into a trans-Ocean aircraft, and how does the improved version stack up against the Boeing 787-9? We use our Aircraft Performance and Cost Model (APCM) to find out.
Figure 1. The A330-900, a model that is selling better and better, 31 years after its introduction. Source: Airbus..
Summary:
- The Airbus A330 is like the proverbial cat; it has many lives. Just when the experts predicted it would slowly go away, it started selling again.
- In the version where it gets another MTOW hike, it can successfully cover transoceanic trunk routes.