AkzoNobel and TAP Air Portugal complete trials of lightweight aircraft coating

AkzoNobel’s Aerospace Coatings business and TAP Air Portugal have successfully completed operational trials of its lightweight Aerobase UPD aircraft basecoat technology, which can reduce coating weight by up to 26 kg per aircraft.

The technology could deliver significant environmental and cost benefits if implemented across TAP Air Portugal’s fleet. Based on projected fleet-wide adoption, Aerobase UPD could generate annual fuel savings of approximately 428.5 tons, resulting in more than €0.5 million in annual cost savings and reducing CO₂-equivalent emissions by around 1,353 tons.

The trials showed that Aerobase UPD can reduce total basecoat film thickness by 36% compared with the previous two-coat system, while maintaining the durability, appearance and finish quality required for commercial aircraft.

“We continuously evaluate opportunities to improve operational efficiency and reduce environmental impact across our operations,” explains João Carvalho, Structures Engineer at TAP Air Portugal.

“The results achieved through this collaboration with AkzoNobel Aerospace Coatings demonstrate how relatively small weight reductions, when applied consistently across aircraft fleets, could contribute to meaningful long-term fuel and emissions savings, while also supporting operational efficiency.

Patrick Bourguignon, Director of AkzoNobel’s Automotive and Specialty Coatings business, adds: “By reducing total film build and simplifying the application process, Aerobase UPD helps operators lower aircraft weight, improve paint shop productivity and maintain the high quality finish standards required across commercial aviation fleets.

“This program with TAP Air Portugal clearly demonstrates how incremental innovations in coating technology can deliver measurable operational benefits and emissions savings for airlines.”

The new formulation achieves the required coverage and finish through a single basecoat application, eliminating the need for a second full layer and the associated flash-off stages. It also provides approximately 40% higher sag resistance than the traditional two-layer system.

Aerobase UPD is certified to AMS3095 standards for global mixed-fleet maintenance, repair and overhaul (MRO) operations. The system is also compatible with the upgraded Aerobase activator and existing Aerobase hardeners, allowing it to be integrated into existing aircraft paint-shop processes with minimal changes.

Source: AkzoNobel