Flight Safety Information - November 5, 2025 No. 221 In This Issue : Crash: UPS MD11 at Louisville on Nov 4th 2025, burst into flames on takeoff : Incident: Ryanair B738 at Cluj on Nov 3rd 2025, first officer incapacitated : UPS cargo jet crashes during takeoff from Louisville hub : Incident: Gulf B789 at Manila on Nov 4th 2025, runway incursion : Caller Reportedly Threatened Plane Would Explode Upon Landing at D.C. Airport, Demands $500,000 in Crypto : Jury selected in US trial against Boeing over 737 MAX crash : Taiwan Lowers Pilot Age Limits : Middle East In Urgent Need Of Pilots : Unraveling Europe’s Unique Airline Safety Rules: Seatbelts and Turnarounds Explained : Bombardier Lowers Global 8000 Cabin Altitude to 2,691 Feet : Beyond fire and smoke: Testing evolves for aircraft cabin interiors : GRADUATE RESEARCH SURVEY REQUEST : Calendar of Event Crash: UPS MD11 at Louisville on Nov 4th 2025, burst into flames on takeoff A UPS United Parcel Service McDonnell Douglas MD-11, registration N259UP performing flight 5X-2976 from Louisville,KY to Honolulu,HI (USA) with 3 crew, was accelerating for takeoff from Louisville's runway 17R at 17:13L (22:13Z) when the aircraft impacted ground and came to a rest at approximate position N38.146 W85.734 about 0.57nm past the runway end and about 0.09nm to the left of the extended runway centerline bursting into flames. All three on board perished, 4 fatalities on the ground are confirmed and 11 injuries on the ground reported, too. The aircraft had already been handed off to departure frequency but did not report on departure frequency anymore. According to ADS-B data the aircraft achieved 185 knots over ground near the aiming markers runway 35L still on the runway centerline but never became airborne. According to pictorial evidence engine #1 (left hand engine, CF6) separated the airframe during rotation for takeoff, the departure of that engine may also have failed the center engine #2. The FAA reported: "UPS Flight 2976 crashed around 5:15 p.m. local time on Tuesday, Nov. 4, after departing from Louisville Muhammad Ali International Airport in Kentucky. The McDonnell Douglas MD-11 was headed to Daniel K. Inouye International Airport in Honolulu. The FAA and NTSB will investigate." Ground observers reported the aircraft had been delayed for about two hours for work on the left hand engine (engine #1), the engine #1 separated during the takeoff run, the center engine emitted streaks of flames, the aircraft impacted a UPS warehouse and ploughed through other facilities before coming to rest in a large plume of fire and smoke. The local governor reported the plane hit two businesses near the airport, the three occupants of the aircraft died, 4 people on the ground are confirmed dead, the death toll could rise. At least 11 people are treated in hospitals for in part serious injuries, that number might rise further, too. The aircraft with 38000 gallons of fuel climbed to about 175 feet AGL before descending again. UPS reported they are halting package sorting at Louisville. The NTSB reported: "NTSB is launching a go-team to investigate Tuesday’s crash of a UPS MD-11 cargo aircraft, Flight 2976 near Louisville, Kentucky. NTSB Board Member Todd Inman will serve as the on-scene spokesperson. The investigative team is scheduled to arrive in Kentucky tomorrow. A media briefing will be held tomorrow, with the time and location to be announced." VIDEO1 VIDEO2 https://avherald.com/h?article=52f5748f&opt=0 Incident: Ryanair B738 at Cluj on Nov 3rd 2025, first officer incapacitated A Ryanair Boeing 737-800, registration EI-DPJ performing flight FR-2682 from Milan Bergamo (Italy) to Cluj (Romania), was descending towards Cluj when the captain declared PAN PAN reporting the first officer had become incapacitated, subsequently the captain upgraded to Mayday. The aircraft landed safely on Cluj's runway 25 and stopped on the runway, where emergency services awaited the aircraft. The first officer, unconscious at that time, was taken to a hospital. About 50 minutes after landing the aircraft was towed to the apron. A replacement Boeing 737-800 registration EI-EPB was dispatched to Cluj and performed the return flight with a delay of about 3 hours. The occurrence aircraft remained on the ground in Cluj for about 17 hours, then positioned to Bucharest Otopeni (Romania). https://avherald.com/h?article=52f50648&opt=0 UPS cargo jet crashes during takeoff from Louisville hub A brown-tailed UPS cargo jet lands on a runway on a sunny day. This UPS MD-11 freighter aircraft (registration N259UP), seen here taking off from Phoenix Skyharbor International Airport on June 28, crashed during takeoff Tuesday afternoon from Louisville airport in Kentucky. An MD-11 freighter aircraft operated by UPS crashed around 5:15 p.m. ET on Tuesday after departing from Louisville Mohammad Ali International Airport in Kentucky, the Federal Aviation Administration confirmed in a social media post. UPS (NYSE: UPS) released a statement saying that three crew members were onboard. Kentucky Gov. Andy Beshear (D) said during a news conference that authorities believe there are three fatalities and 11 injuries, some of them significant. Injured people are being treated at local hospitals. The governor said the number of fatalities and injuries is expected to rise. Louisville is the location of UPS Worldport, the express carrier’s global air hub. UPS said package sorting operations at the facility have been suspended for the night. The Louisville airport said on X that the airfield is closed because of an incident and that all arriving and departing and arriving flights are temporarily suspended until 7 a.m. on Wednesday. “We are terribly saddened by the accident tonight in Louisville. Our heartfelt thoughts are with everyone involved. UPS is committed to the safety of our employees, our customers and the communities we serve. This is particularly true in Louisville, home to our airline and thousands of UPSers,” UPS said in a statement. The aircraft was fully loaded with thousands of gallons of fuel when it struck the ground. Social media posts show the tri-engine plane erupting in flames on impact with the ground. WLKY local news helicopter video shows the plane crashed into a group of warehouses and industrial buildings beyond the runway near Grade Lane, with flames and black smoke continuing to grow as fuel catches on fire. The destruction is widespread. Among the properties that were struck were Kentucky Petroleum Recycling and Grade-A Auto Parts. A photo posted on Reddit shows a large warehouse with a major gash where the plane made impact. Grade-A Auto Parts has reported that two employees are missing and unaccounted for, Beshear said. The local Ford assembly plant was not hit, but has lost power and has closed production. The Louisville Metropolitan Police Department and multiple agencies have responded to the crash. People living and working north of the airport to the Ohio River are being asked to shelter in place because of the smoke inhalation hazard. The widebody cargo jet was bound for Daniel K. Inouye International Airport in Honolulu, the FAA said. The FAA and the National Transportation Safety Board will investigate the accident. https://www.yahoo.com/news/articles/ups-cargo-jet-crashes-during-235222131.html Incident: Gulf B789 at Manila on Nov 4th 2025, runway incursion A Gulf Air Boeing 787-9, registration A9C-FJ performing flight GF-155 from Manila (Philippines) to Bahrain (Bahrain), was taxiing for departure from Manila's runway 06 when the crew missed the turn onto the parallel taxiway and entered runway 06 without clearance effectively backtracking the runway. Tower instructed the next arrival on final approach to go around and GF-155 to vacate the runway onto the taxiway at the next turnoff. A PAL Express Airbus A320-200, registration RP-C8611 performing flight PR-2986 Tacloban to Manila (Philippines), was on short final to runway 06 when GF-155 entered the runway and ATC instructed them to go around. The aircraft positioned for another approach and landed safely about 20 minutes later. The Boeing 787-9 vacated the runway, taxied to the hold short line and departed about 8 minutes later. https://avherald.com/h?article=52f503ed&opt=0 Caller Reportedly Threatened Plane Would Explode Upon Landing at D.C. Airport, Demands $500,000 in Crypto The FBI later confirmed on X that 'no hazards were found' The runway at Ronald Reagan Washington National Airport closed for over an hour after an unconfirmed bomb report on an inbound United Airlines flight According to the Washington Post, someone called into the air traffic control tower, demanded $500,000 in crypto and said United flight 512 would explode upon landing United confirmed to PEOPLE in a statement that all 89 passengers deplaned safely on the tarmac and were bussed to the airport A bomb threat was reportedly called into the air traffic control tower at Ronald Reagan Washington National Airport (DCA) on Tuesday. Department of Transportation secretary Sean Duffy said on X that a United Airlines flight from Houston to Washington D.C. received a bomb threat. The Washington Post reported that according to their sources close to the situation, a person had called the airport’s air traffic control tower and requested a $500,000 cryptocurrency payment. They had insisted that United flight 512 would explode upon landing, according to the sources. “I’m sorry to have to do this to you. We’ve got to turn you, again,” an air traffic controller tells the United pilots in a radio recording obtained by LiveATC.net. “We have an unconfirmed bomb report for your flight, we got to get you away from the airport.” A few moments later, the air traffic controller explained more details regarding the report. “I mean, I can confirm someone called. Someone called and said there was a bomb on [United flight] 512, they said if it landed, it would explode — well, it landed,” he says. A spokesperson for Delta confirmed to PEOPLE in a statement that United flight 512 “landed safely after a potential security concern.” All 89 passengers deplaned and were bused to the terminal. After law enforcement searched and cleared the aircraft, the Boeing 737 Max 8 taxied to the gate. “The flight landed safely at DCA, passengers were evacuated, and law enforcement conducted a full search of the aircraft,” Duffy wrote on X. “The @FAANews has received the all clear and operations have resumed.” The FBI confirmed its Washington Field Office’s National Capital Response Squad responded to the scene and “no hazards were found,” according to a post on X. “The FBI continues to work with our law enforcement partners on this investigation.” According to DCA’s website, the runway closed for over an hour before flights resumed at the D.C. area airport around 12:50 p.m. local time on Nov. 4 following an 80-minute closure of the runway. On X, Reagan Airport confirmed “several flights were diverted to other airports during the runway closure.” Adding, “People meeting passengers or flying this afternoon should expect delays and check with their airline for updated flight information.” https://www.yahoo.com/news/articles/caller-reportedly-threatened-plane-explode-221014917.html Jury selected in US trial against Boeing over 737 MAX crash Opening arguments will begin in Chicago on Wednesday in the first civil trial against US aviation giant Boeing over the 2019 crash of an Ethiopian Airlines 737 MAX aircraft, which killed 157 people, after a full day of jury selection. Five women and three men will serve on the jury in the proceedings, which got underway Monday at a federal court. The jury will rule on the suits filed by family members of 155 victims between April 2019 and March 2021, alleging wrongful death and negligence, among other claims. On four prior occasions, attorneys reached last-minute settlements that averted a trial, and an out-of-court settlement remains possible even during the trial. Each side will have 90 minutes on Wednesday to present its case. Judge Jorge Alonso, who is overseeing all civil claims tied to the accident, allowed lawyers on Tuesday to participate in the process, Robert Clifford, lead counsel for one of the plaintiffs, told AFP. "I think his goal was to get as unbiased a jury as he could obtain," he said. "Even if he asked a lot more questions than maybe would be normal... it wouldn't have surprised me that a case as complex as this could easily have taken two days to select a jury." - 'Battle lines are drawn' - Lawyers for Boeing and the families of victims of the fatal crash were originally expecting to give opening statements on Tuesday, but those were pushed to the next day because it took six hours to finish jury selection. As many as 50 potential jurors packed the courtroom on the 19th floor of the Dirksen Federal Courthouse on Tuesday, while the public filled the pews on the other side. With the jury selected, it is less likely that the two parties will settle the case, Clifford said, adding that the plaintiffs have not talked with the defendants about settling. "The battle lines are drawn and there's no active negotiations going on," the lawyer said. The eight-person jury that was picked will be hearing the case concerning the March 10, 2019, Ethiopian Airlines flight that went down six minutes after departing Addis Ababa for Nairobi, killing all on board. The two principal plaintiffs in the trial are the families of Shikha Garg of New Delhi and Mercy Ndivo of Kenya. Garg had been a consultant for the United Nations Development Program who had been traveling to Nairobi for a UN Environment Assembly. She had gotten married three months earlier and had planned to travel with her husband, who canceled his flight at the last minute because of a professional meeting. Garg had attended the landmark 2015 UN climate talks in Paris. Ndivo and her husband, who also died in the crash, were parents of a girl who is now almost eight years old. She was returning from London, having attended a graduation ceremony after earning a Masters in Accountancy. Boeing has said it is "deeply sorry" for the Ethiopian Airlines crash and for a separate MAX crash on Lion Air that killed 189 people on a domestic flight in Indonesia in 2018. The American manufacturer has also stressed its commitment to settling cases when possible. The firm has "accepted responsibility for the MAX crashes publicly and in civil litigation because the design of the MCAS... contributed to these events," a Boeing lawyer said last October. The MCAS (Maneuvering Characteristics Augmentation System) flight stabilizing software was implicated in both the Ethiopian Airlines and Lion Air crashes. Boeing also faced dozens of complaints from Lion Air family victims. Just one case remains open. https://www.yahoo.com/news/articles/us-civil-trial-hear-opening-054309601.html Taiwan Lowers Pilot Age Limits Civil aviation authorities look to align pilot age limits with ICAO, EASA and FAA. Taiwan’s Ministry of Transportation and Communications announced Tuesday that it has revised the Regulations Governing the Certification and Qualification of Aviation Personnel, lowering the minimum pilot age requirements for pilot certification to expand the supply of qualified flight crews. The changes reduce the minimum pilot age for commercial and multi-crew certification from 20 to 18, and for airline transport pilot certification from 23 to 21. The ministry said the adjustments bring Taiwan’s standards more closely in line with the International Civil Aviation Organization (ICAO) and European Union Aviation Safety Agency (EASA), as well as the practical needs of aviation license management. The amendments also raise the pilot age limit for airline operations to 65, a move officials said would improve scheduling flexibility for airlines. The Civil Aeronautics Administration (CAA) noted that pilots over 60 must receive medical examinations every four months. While ICAO allows both pilots on international routes to be older than 60, Taiwan will maintain its rule permitting only one pilot over that age on such flights. The CAA said the revisions were informed by regulatory practices observed in other major aviation markets. This rule has been called into question by some governments recently, including in the U.S., where senators have argued for an increase to 67. The CAA said Taiwan’s decision to align with those international benchmarks supports the country’s goal of harmonizing safety and certification frameworks while helping address the aviation industry’s growing demand for qualified pilots. https://avweb.com/aviation-news/taiwan-lowers-pilot-age-limits/ Middle East In Urgent Need Of Pilots The Gulf region is booming, and even non-oil Arab states like Egypt are back on a growth path, according to the IMF. However, a persistent shortage of pilots is slowing the Middle East’s ambitions in civil aviation. According to a study this is also due to the professional philosophy of young airline captains. According to the «Flight Operations Report 2025», published by Oliver Wyman, airlines in the Middle East will need an additional 10,300 pilots by 2030. «While shortages in North America and Europe are gradually easing, the Middle East remains the only region where the demand for pilots continues to significantly exceed supply,» the study states. Growing Networks, New Players However, the staffing shortages in cockpits and the industry’s ambitions are at odds, as airlines across the region are aiming high. The major carriers—Emirates (Dubai), Etihad (Abu Dhabi), Qatar Airways (Doha) and Saudia Airlines have been steadily expanding their route networks or adding new destinations since the end of the pandemic. The state-owned airline Emirates, for example, has been flying since mid-2025 to new destinations such as Shenzhen and Hangzhou in China, as well as—after a 13-year hiatus—back to the Syrian capital, Damascus. Qatar Airways has entered the South American market, adding Bogotá, Colombia, with a continuing flight to Caracas, Venezuela, to its schedule. Recently, Riyadh Air from Saudi Arabia entered the market, aiming to serve over 100 destinations by 2030. Good Career Prospects for Aspirants From Overseas Oliver Wyman expects that these airlines will continue to attract foreign pilots with tax-free salary packages and expanded opportunities to operate long-haul aircraft. However, «the report notes that the gap is likely to widen further, as younger pilots increasingly value work-life balance, flexibility, and control over their schedules more highly than traditional pay and promotion models,» says André Martins, Head of Transportation and Advanced Industrials for India, the Middle East, and Africa at Oliver Wyman in Dubai. At the same time, personnel costs—driven by higher salaries and new labor regulations—are rising faster than airline revenues, putting additional pressure on flight operations managers,» Martins adds. Further Middle Eastern aircraft orders are expected to be finalized at the upcoming Dubai Airshow, which will take place from November 17 to 21 2025. https://www.finews.com/news/english-news/70010-middle-east-airlines-need-of-pilots-study-oliver-wyman Unraveling Europe’s Unique Airline Safety Rules: Seatbelts and Turnarounds Explained When we think of airline safety, the first thing that usually comes to mind is the constant reminder to fasten our seatbelts. Airlines around the world, including in Europe, stress the importance of keeping seatbelts fastened, even when the seatbelt sign is off. However, there’s a surprising exception to this rule during a specific time: the turnaround process. What Is the Turnaround Process? The turnaround is the phase where an airplane prepares for its next flight after passengers disembark. For many European airlines, this time is crucial as they aim to get the plane ready as quickly as possible for the next set of passengers. The idea is simple: an airplane on the ground is not earning money. Airlines, especially those with short-haul flights, aim to keep planes in the air as much as possible during the day. For example, Ryanair, Europe’s largest low-cost airline, is famous for its incredibly fast 25-minute turnaround. In this time, everything must happen simultaneously: unloading passengers, offloading baggage, and refueling the plane. This high-paced process has one significant caveat: passengers need to keep their seatbelts unfastened while refueling is taking place. Why Refueling Makes Seatbelt Use Dangerous This policy seems strange at first, especially since we’re so used to hearing about the importance of seatbelts. The reasoning behind this practice is safety-driven. Aviation regulators in Europe have determined that refueling presents a fire risk, and in the rare case of an emergency, they want to ensure there are no delays when evacuating passengers. The theory is simple: if a fire were to occur during refueling, a fast exit could be the difference between life and death. For this reason, European airlines ask passengers to unfasten their seatbelts while refueling is underway, which allows for a quicker evacuation if necessary. It’s crucial that passengers can quickly exit the aircraft in an emergency, and wearing a seatbelt during refueling could slow down that process. The Key Difference Between Europe and the US In contrast, the rules in the United States are slightly different. US airlines, under FAA guidelines, typically allow passengers to wear their seatbelts during refueling, provided the boarding door remains open until the process is complete. While some US airlines follow a similar practice to European carriers by requesting seatbelts to be unfastened during refueling, it’s not a universal mandate across the board. The primary distinction lies in how the US ensures that the door stays open, which serves as a safety measure during the refueling process. Other Surprising Safety Differences in Air Travel The seatbelt rule during turnaround is just one example of how airlines differ in their safety practices across the world. In many countries, it is a standard procedure to have window shades open during taxi, takeoff, and landing. This is to ensure passengers are aware of their surroundings and can quickly adjust their eyes if evacuation is necessary. Another lesser-known rule involves USB cables and chargers. On many international airlines, passengers are required to unplug these devices before takeoff and landing, as they could pose a tripping hazard in an evacuation. Similarly, hand luggage is banned from certain emergency exit rows to minimize obstacles in the event of an emergency. In the US, infants under the age of two are not allowed to be secured by a special infant seatbelt attached to the parent’s seatbelt, a practice allowed in many other parts of the world. What This Means for Travelers For travelers flying through Europe, understanding the reasons behind these unique safety practices can provide peace of mind. It’s a reminder that every airline, and country, has its own approach to safety. The turnaround process, though it may seem like a small detail, has significant implications for how airlines operate efficiently while maintaining high safety standards. So, the next time you’re traveling on a European airline, don’t be surprised if you’re asked to unfasten your seatbelt. It’s simply a precaution to ensure you can exit the plane quickly in case of an emergency during refueling. And while this may not be something you’ll encounter on all airlines globally, it’s a key part of the safety culture in Europe. Conclusion: The Unique Safety Measures of European Airlines European airlines have crafted their own set of safety protocols that set them apart from their counterparts in the United States and other parts of the world. From the quick turnaround times to the seatbelt rules during refueling, these measures prioritize efficiency and safety for all passengers. Understanding these differences can make travel feel safer and more transparent, so you’re always prepared for what’s to come. https://www.travelandtourworld.com/news/article/unraveling-europes-unique-airline-safety-rules-seatbelts-and-turnarounds-explained/ Bombardier Lowers Global 8000 Cabin Altitude to 2,691 Feet Global 8000's predecessor, the 7500, has a 2,900-ft cabin altitude at FL410 Bombardier has reduced the cabin altitude of its Global 8000 to 2,691 feet at FL410, a threshold the Canadian manufacturer claims as the lowest in the industry. Announcement of the reduced cabin altitude—which compares with the 2,900 feet of the ultra-long-range twinjet’s Global 7500 predecessor—comes as the aircraft approaches certification and just weeks after Bombardier confirmed a Mach 0.95 top speed for the Global 8000, another high watermark in the business aviation sector. Bombardier stressed the cabin altitude's importance for passenger well-being. “The ultimate comfort in the sky is feeling like you’re at home. We have focused heavily on elevating the passenger experience, imperative priorities for ultra-long-range travel,” said Stephen McCullough, senior v-p of engineering and product development at Bombardier. Along with the lower cabin altitude, Bombardier incorporates a Pũr Air system with HEPA air filtration for fresh air onboard the long flights. Bombardier said the Global 8000 remains on track to enter service by year-end. https://www.ainonline.com/aviation-news/business-aviation/2025-11-04/bombardier-lowers-global-8000-cabin-altitude-2691-ft Beyond fire and smoke: Testing evolves for aircraft cabin interiors Alongside flammability, smoke release and other tests, Gen Phoenix puts its engineered leather products through a variety of mechanical trials Airliner cabins contain an array of materials including adhesives, coatings, composites, electronic components, metals, plastics and textiles, all tested for compliance to strict regulations. Add private and VIP jet cabins into the mix and the scope widens thanks to the often exotic items that corporations, heads of state and wealthy individuals specify for their bespoke cabins. Federal Aviation Regulation 25.853 is one of the industry’s key guides, setting flammability standards for cabin materials. Gen Phoenix supplies leather for airliner seat covers and its product is unusual. “All our materials designed for aviation undergo rigorous safety and compliance testing to meet or exceed global industry standards, including flammability, heat release, smoke density, and toxicity requirements,” says Nico Den Ouden, chief innovation officer. “These tests are performed in certified third-party labs, often in accordance with standards including Federal Aviation Regulation 25.853.” Gen Phoenix manufactures its leather product from wet blue leather trimmings and shavings, products of the traditional leather tanning process which otherwise go to landfill or are incinerated. It reduces the feedstock to individual fibers before reconstituting it into what Den Ouden describes as “engineered leather.” “It behaves differently to traditional leather,” he says. “Engineered leather can be tailored at the fiber and composite level, allowing us to optimize performance for fire safety and ensure consistency across every production batch, something that’s harder to guarantee with natural hides.” PAINT & COATINGS Coatings, including paint and a variety of textured finishes, are so prevalent throughout the cabin they are easily overlooked. Sherwin-Williams Aerospace manufactures a wide variety of aircraft cabin, exterior and structure coatings. “Everything in the pressurized portion of the aircraft, including the cabin and cargo areas, must meet those Federal Aviation Regulation requirements,” says Grant Semanskee, aerospace account executive at Sherwin- Williams. “We test our products and then the OEMs test composites, honeycomb and other materials finished with our coatings against their own specifications. Later in an aircraft’s career, if those components are refurbished they must be treated with the same coatings, otherwise they must be retested.” With its roots in a traditional cabinetmaking, Austria’s F/LIST specializes in materials and monuments for executive jet cabins, yachts and luxury residences. It employs a variety of regular cabin materials, more exotic items including wood and stone veneers and, increasingly, materials developed in-house for sustainability and their potential for recycling. Martindale abrasion testing underway in the lab at Gen Phoenix’s Peterborough, UK headquarters “We test completed products once we’ve established that all components are airworthy to the relevant certification standards,” explains Patrick Domnanich, F/LIST director research and development. F/LIST product test reports regularly run to 100 pages or more, detailing tests for flammability, durability analyzing for stretch resistance, strength, scratch resistance and more, with working parts subject to repetitive test to establish longevity, heat and humidity up to 98%, cycling up and down to emulate temperature fluctuation, ultraviolet damage since discoloration is a significant issue, and damage from liquids and chemicals, including acid and alkaline food spills, with lemon juice, tea, coffee and wine among them. “We have in-house facilities for all testing,” Domnanich adds. “This enables us to trial finished products and makes for agile development with quick iterations and reduced response times to customer requests. In-house validation testing means we know that what we’re supplying is airworthy before we deliver to our customers.” Wood veneers have an important place in many private jet cabins and Domnanich remarks upon F/LIST’s database on tree species that it has pre-tested. “With 20 years of experience in aviation, we are rarely asked to specify a type of wood that we haven’t previously tested,” he says. “When we receive such a request, we build up a flammability sample and test onsite in one of our chambers. Strips of the material are exposed to a flame for 60 seconds. The extent of damage suffered, the time it takes for the material to extinguish after the flame is removed and the dripping of burning material must be minimal.” SCUFFS AND STAINS Safety is the primary driver in cabin materials testing, but manufacturers must also prove their products’ ability to resist scuffs and stains in daily and typically heavy use. Airliner seats, for example, are occupied for many hours every day, cleaned regularly and must take knocks and spills in their stride. “Durability is a cornerstone of the Gen Phoenix offer, proven through a range of performance tests, including Martindale abrasion, flex resistance, ultraviolet stability and colorfastness to light and rubbing,” Den Ouden says. “We also test compatibility with aviation-grade cleaning agents, simulating repeated exposure over the material’s lifetime. In ingress/egress simulations, mimicking years of passenger movement, our seat cover materials have shown minimal signs of wear, even after more than ten years of simulated use.” Stain resistance is another, perhaps less obvious challenge, with the worst offending contaminants including coffee, curry powder, ink, ketchup, lipstick, mustard, red wine, shoe polish and sunscreen. “Testing is conducted over a 12-hour period, with assessment focused on staining and surface degradation,” Den Ouden says. “Additionally, a broad selection of typical cleaners and sanitizers has been screened for compatibility using various methods to confirm that the surface finish and overall integrity of the product remain unaffected.” “Our textile surfaces undergo abrasion and aggressive light-fading tests, and we assess color fastness to rubbing and water, ensuring color doesn’t leach on to garments or skin,” Domnanich says. “We always check that ingredients meet the highest standards when it comes to human health too.” Sherwin-Williams proves the resilience of its coatings against fluids and staining. “Our performance testing ensures a coating’s longevity,” says Julie Voisin, market segment manager, aerospace, original equipment automotive interiors and commercial vehicle refinish at the company. “We assess how stains will clean off and whether the cleaning process will damage the coating. We have decades’ worth of data on the performance of our Polane L coating, manufactured to Boeing’s BMS 10-83N specification and used in the most difficult, high-traffic cabin areas, showing its resilience in testing and daily use.” NEW AND EXOTIC MATERIALS Gen Phoenix is taking its engineered leather to new heights with a completely circular production process. Generating an identical product to that produced by today’s wet blue feedstock, the new concept recycles used leather into new material. The feedstock could be leather from aircraft seat covers, post-consumer clothing, accessories and footwear, or even Gen Phoenix’s own product at end of life. “Before any new material stream is adopted, it undergoes extensive R&D and validation to ensure compatibility with our manufacturing platform and to maintain consistent downstream performance,” Den Ouden explains. “Our system requires all incoming feedstock to be processed to a defined specification in terms of fiber structure, chemical treatment and contamination level. This enables us to create a high-quality, consistent material regardless of the original product’s prior use.” An F/LAB product, Linfinium is made with linseed oil and typifies the company’s use of non-traditional aviation products and waste materials, since Linfinium is available in a variety of finishes and textures including, among other items, mother of pearl fragments and waste marble Any product incorporating new feedstocks then undergoes a full requalification process, which includes repeating all necessary safety and performance tests to ensure continued compliance in aviation and other regulated industries. “Our qualification protocols for new feedstocks are guided by market requirements and may involve laboratory testing and simulated use to evaluate factors including durability, fire performance and tactile properties,” Den Ouden says. “Additionally, chemical characterization will be conducted to ensure the ongoing consistency of incoming materials.” In its quest for sustainable, even circular cabin materials, F/LIST has developed a range of biomaterials, often incorporating waste products, and unique cabin monuments. The company’s Shapeshifter products perform seemingly magical manipulations with wood and other materials. “We created new actuation mechanisms, which in turn required the development of new testing equipment, for our pneumatic actuation, for example,” Domnanich says. “The work included design and development of printed circuit boards and software for the actuation logic and the testing station.” The new materials effort employs an interdisciplinary team of chemists, wood scientists, textile and sustainability experts, and F/LIST also works with partners in the fashion and automotive industries to bring their material technologies into aircraft cabins. Whatever the material, Domnanich says validation is extremely rigorous. “Our benchmark is the performance of today’s conventional materials, because customers will not compromise on durability,” he says. “We conduct chemical, mechanical and flammability testing, as well as testing how materials perform in an application. A sustainable leather alternative must be tested for elasticity, wrinkling behavior and color stability for example. “The challenge with sustainable materials is not so much the chemistry but more in securing reliable and verifiable raw material streams. Controls and tests ensure raw materials, which are frequently plant-based and inherently variable, meet aircraft requirements.” Considering the potential for business and VIP jet cabins to include a wide variety of traditional aviation materials and exotics in combination, the process of ensuring and documenting compliance presents its own challenges. Camber Aviation Management oversees cabin completion and refurbishment projects, with a particular emphasis on bizliners, typified by the Airbus ACJ and Boeing BBJ airliner-based VIP aircraft. “In any VIP or VVIP completion, there’s a very clear regulatory framework,” says Tom Chatfield, Camber’s CEO. “Responsibility for ensuring all materials pass the required tests rests with the completion center that sources certified materials and ensures they fulfill regulatory requirements. The work required to prove compliance includes various burn tests, applicable for each batch of material as well as different material build-ups.” As completion manager, Camber acts as the client’s advocate in this process, ensuring the completion center’s approach is thorough, transparent and properly documented. “We review test results, verify the traceability of materials, and make sure nothing slips through the cracks,” Chatfield says. “The results of these tests form part of the aircraft’s certification and, ultimately, delivery package.” VIP clients frequently want exotic woods, textiles and other materials they have seen in luxury homes or yachts for their aircraft cabins. “Even a seemingly harmless finish might produce unacceptable smoke density or toxic emissions,” Chatfield cautions. “That’s why testing, and often reformulation or substitution, is essential.” Completion centers must also account for differences in regulation based on passenger capacity. “Business jets and commercial airliners converted into large bizliners must meet the same overarching safety standards for flammability, smoke density and toxicity for interior materials as defined by regulations including Federal Aviation Regulation 25.853,” Chatfield says. “However, the scale and complexity differ. The requirements for flammability change considerably between cabins designed for 19 or fewer passengers and those designed for 20 or more, with the latter far more stringent. The ACJ and BBJ platforms therefore bring additional certification requirements, potentially broadening the testing scope, and more rigorous documentation, especially when local authorities are involved in the approval process.” Chatfield says that in complex VIP completions assumptions over testing and compliance occasionally arise, especially when a center deals with new suppliers or highly customized features. Recognizing that safety is always the critical factor, his further comments on such assumptions resonate across the aviation industry. “It’s why oversight like ours matters,” he says. “We maintain independent tracking and reviews to ensure no material is installed without clear, traceable proof of compliance, safeguarding the owner’s investment, the aircraft’s long-term value and safety.” https://www.aerospacetestinginternational.com/features/beyond-fire-and-smoke-testing-evolves-for-aircraft-cabin-interiors.html GRADUATE RESEARCH SURVEY REQUEST Dear Fellow Pilot, Researchers at Embry-Riddle Aeronautical University are conducting a study to better understand the mental health of professional pilots and the barriers they may face in seeking support. If you are currently a professional pilot, working in any sector and region of the global aviation industry, you are invited to participate in this anonymous, voluntary survey. The survey includes questions on anxiety, depression, self-stigma, and attitudes toward disclosing mental health concerns to civil aviation regulatory bodies (e.g., FAA, EASA, CAA, ANAC, etc.). It takes approximately 15 minutes to complete. No identifying information or IP addresses will be collected, and all responses will remain completely confidential. Your participation will help identify key challenges and support the development of resources and industry practices that prioritize pilot well-being and safety. Thank you for your time and contribution to this important research. Link to the Survey Questionnaire https://forms.gle/AnJuk3TZ2u96SpFq9 Thank you very much for your time and consideration. Please let me know if you have any questions or would like to discuss this further. Best Regards, Bill Deng Pan Ph.D. in Aviation Student CALENDAR OF EVENTS . 78TH ANNUAL INTERNATIONAL AVIATION SAFETY SUMMIT (IASS) - Lisbon, November 4–6 . 29th annual Bombardier Safety Standdown, November 11-13, 2025; Wichita, Kansas · CHC Safety & Quality Summit, 11th – 13th November 2025, Vancouver, BC Canada . 2026 ACSF Safety Symposium; April 7-9, 2026; ERAU Daytona Beach, FL . 2026 NBAA Maintenance Conference; May 5-7, 2026; New Orleans, LA . BASS 2026 - 71st Business Aviation Safety Summit - May 5-6, 2026 | Provo, Utah . The African Aviation Safety & Operations Summit - May 19-20 | Johannesburg, South Africa . Safeskies Australia - Australia’s renowned Aviation Safety Conference - Canberra Australia 20 and 21 May 2026 . 2026 NBAA Business Aviation Convention & Exhibition (NBAA-BACE) Oct. 20-22, 2026 | Las Vegas, NV Curt Lewis