Skin Deep

A good paint finish can give passengers confidence that the aircraft is well maintained but is also working hard at protecting the aircraft itself. Ian Harbison reports.

Aircraft paints and coatings are about much more than decoration. They have to look good, of course, but they must also protect the aircraft under harsh conditions and last as long as possible, ideally until the next heavy check where paint has to be removed anyway for structural inspections. Application is equally critical, with a need to ensure even coverage while taking care of environmental concerns.

Mankiewicz

René Lang, executive managing director aviation at Mankiewicz, says basecoat/clearcoat is definitely the standard system for painting commercial aircraft. This consists of a solid color layer that is oversprayed with a clear polyurethane protective coating. In addition to protecting the basecoat, the clearcoat provides strong UV protection to prevent fading and a high gloss finish (high Distinctness Of Image, a function of the sharpness of a reflected image from a surface when measured using a DOI meter). It is also used to carry special finishes like mica for a metallic look.

He says durability and longevity are key decision-making criteria for OEMs when choosing paint for new aircraft. The aim is to deliver an aircraft that requires as little refurbishment as possible. A Boeing 737-800 of Canadian carrier Westjet was given a Disney-themed special scheme using the company’s ALEXIT system, which lasted for 10 years before being repainted, although this was because the cooperation between WestJet and Disney ended.

Another advantage of ALEXIT is the combination of fast-drying and high-coverage, saving time in the application process. This is crucial nowadays, he says, as, looking at the order books of manufacturers around the globe, it is evident that production capacities will be fully utilized in the coming years. Every adjustment that helps to complete the painting process as quickly as possible is beneficial. The use of systems, such as ALEXIT BaseCoat/ClearCoat, is a real lever here in reducing the turnaround time of special liveries.

The ALEXIT BaseCoat/ClearCoat system features flexible application properties, including adjustable drying times, which accommodate large areas with good overspray uptake and fast drying properties for smaller areas. The most significant advantage is that the paint system enables the so-called wild spraying technique, reversing the classic painting process sequence. Instead of starting with the most frequent color, the lowest is applied first. In a standard procedure, you would begin by spraying the most frequently used color first (typically white), followed by the less frequently used colors in sequence. The original process requires an intensive workforce and materials are needed to mask the aircraft between paint applications.

Wild spraying also allows for spraying two colors at the same time, provided that they are not too close to each other, to avoid overspray. Mica and other special effect coatings are a design upgrade that airlines consistently choose to use. This is a great option, he comments, especially when it comes to giving brand reputation an additional boost in terms of high premium status. This works well with small mica accent areas, as well as in full-body mica variants. He says ALEXIT has been designed to give a uniform high-class finish even used on the complete fuselage, as Etihad Airways, and National Airlines have successfully demonstrated.

Examining the business aviation sector, aircraft owners often have very special and unique design requirements. The mica effect is usually a good choice for these smaller aircraft to create a perfect, customized look.

Special liveries are always lighthouse projects for all parties involved — the airline, the paint crew, and the paint manufacturer — and needs close cooperation. There have been two recent projects of note. The first was for Brussels Airlines, with an Airbus A320neo used to promote the annual Tomorrowland music festival in Antwerp. This featured Augmented Reality, as the bird design comes to life when scanned with a smartphone. This was painted by Airbourne Colours (see below). The second was a special version of the Condor Flugdienst striped livery in the colors of German soccer club Eintracht Frankfurt.

Lang says re-thinking state-of-the-art processes and products is a valuable approach that has led to various innovations like the first basecoat/clearcoat system implemented by Mankiewicz many years ago. The latest innovation, ALEXIT WingFlex, allows the top and bottom surfaces of the wings to be coated with a single product — previously, two different coating systems were used.

This is because the upper side requires high flexibility and UV resistance to withstand the impact of considerable compression caused by movement and sunlight, while the lower surfaces must resist harsh chemicals like hydraulic fluids.

Combining these contrasting requirements speeds up application time but also allows for touch-up and repair in service which was not possible before, saving process time, downtime, money and, in the end, unscheduled maintenance or early refurbishment.

He says that, as a paint manufacturer, the market has completely recovered in the post-pandemic period. It is reaching new heights, considering the flight numbers of the current fleets and their growth potential, along with the full order books of the OEMs around the globe. The continuing rise in demand and high passenger volumes also make it clear that both the OEM market and the MRO market offer significant growth potential, while exerting a very high, positive pressure to innovate. This is because both markets need paint systems that shorten the painting process, continuously extend the durability and performance of the paint, and match the perfect colors for the airlines’ brands and special liveries.

Sherwin-Williams

Julie Voisin, aerospace market manager, explains that development is divided between four “buckets”:

• Productivity improvements focus on how OEMs and MROs work more efficiently and do their job faster.

• Environmental improvements include the reduction of VOCs, removal of harmful chemicals and the introduction of chrome free solutions.

• Durability ensures coatings maintain their appearance and performance throughout the entire paint cycle.

• Color improvements include delivering unique finishes and special effects to meet aesthetic demands.

However, she adds, during the development process it sometimes happens that a new product will have applications beyond just one category. For example, Jet Prep pre-treatment, a chrome-free product developed for environmental improvements, turned out to improve productivity by being faster to apply, reducing the time to the start of primer application. The same happened with two new chrome-free primers that reduced the time to start painting.

The drying time for the CM0ACC201 Aerospace Clearcoat for general aviation aircraft is an example of productivity as the drying time can be modified by blending activators in different ways. Dan Szczepanik, global marketing director automotive division, points out that in automotive, speed is of the essence, in application and drying. This is also important for aviation repairs, but the much larger surface areas involved with aircraft, especially widebodies, means that smooth paint flow and longer drying times are more important. Voisin adds that the blending of activators is again a key factor in establishing the correct drying time for a given area.

Szczepanik points out that aircraft owners want to express themselves through their paint scheme, so color is extremely important. The company offers a web-based Aircraft Color Visualizer. In March 2025, it added four more generic aircraft types — high wing piston, light twin, high wing turboprop and low wing turboprop — to the existing models of a kit plane, single piston, twin turboprop, light business jet, heavy business jet and helicopter.

It allows users to customize the selected model with any color in the Sherwin-Williams aircraft color library and instantly view the combination on screen. The pre-designed schemes can integrate one base color and up to three accents, in both solids and metallics. The Aircraft Color Visualizer allows users to print, save and share their finished designs and they also can be referred to a professional aircraft designer to fulfil their vision on their specific aircraft.

Voisin says for business aviation, there is a clear divide between those who want to remain anonymous and those who want to show off their brand. She also feels that, generally, European customers are more adventurous with colors than those in North America.

Regarding special effects and unique finishes, Sherwin-Williams’ latest 850 Series SKYscapes Effect Finishes is a high-performance polyurethane basecoat available as mica, metallic and hybrid finishes. This is specially designed for productivity and can be used from striping and accents to overall paint completion of commercial aircraft.

AkzoNobel

AkzoNobel is committing €50 million ($58.6 million) to modernize its Waukegan, Illinois, site — the company’s largest aerospace coatings manufacturing facility worldwide.

The two-phase investment will expand production capacity through new equipment and higher levels of automation, while also adding a new warehouse facility just over the state line in Wisconsin. Together, the company says these upgrades are designed to strengthen its North American supply network and support future growth.

“This investment enhances our end-to-end supply capabilities across North America and reinforces our leadership in aerospace coatings,” says Patrick Bourguignon, director of automotive and specialty coatings. “With air travel demand set to rise significantly in the coming years, we want to ensure our customers can meet that growth with aircraft finished to the highest standards.”

The 11-acre Waukegan site employs around 200 people and manufactures a broad portfolio of aerospace coatings, including primers, basecoats, clearcoats and pre-treatment products. The facility also houses its own dedicated color center.

Planned enhancements include the introduction of a liquid pre-batch area, the installation of high-speed dissolvers, and the creation of a rapid service unit aimed at shortening turnaround times for customers in the MRO market.

AkzoNobel says relocating warehousing operations to Pleasant Prairie, Wisconsin, will free up additional space at its Waukegan site, allowing for increased production of customized coatings and faster responses to customer requirements.

“Our customers expect — and deserve — best-in-class coatings,” adds Martijn Arkesteijn, global operations director for aerospace coatings. “These investments will give us greater flexibility, enabling larger batch deliveries, improved responsiveness to market needs, and shorter lead times for color development.”

Airbourne Colours

A frequent customer for products from both companies (as well as AkzoNobel and PPG) is U.K.-based Airbourne Colours, which celebrated 15 years of operation in November with the opening of a second facility at Teeside Airport. The 27,000-sq-ft unit brings up to 40 jobs and will be capable of accommodating narrowbody aircraft, including the Airbus A321 and Boeing 737 MAX 10.

Remarkably, the first facility, the same size, only opened for business in October 2024. This is due to a resurgent airline market, says Simon Cracknell, sales and marketing director, giving the company an annual turnover of more than £12 million (approx. $16 million) with a customer base that includes Brussels Airlines, easyJet, Jet2, Loganair, Lufthansa, Smartlynx, SAS and TAP Portugal. He adds that, in the last five years, there has a been trend for major airlines to outsource work rather than operate their own paint facilities.

Teeside complements the original paint shop at Bournemouth. This was followed by an A321-sized bay at East Midlands Airport in 2014 with a second bay commissioned a year later. In March 2016, the business expanded its capabilities with the creation of Airbourne Graphics & Signs, supporting both aviation clients and a variety of other industries.

In March 2023, another facility came online at Exeter Airport, capable of handling business and regional aircraft up to the size of an ATR 72. This was followed in October by the launch of Airbourne Executive at London Biggin Hill Airport, to provide painting for components such as control surfaces and landing gear. Customers include Bombardier, Gulfstream, Harrods Aviation and Inflite Engineering. In addition, the company deploys self-sufficient teams to customer sites for small jobs such as repairs. Business aviation now accounts for about 20% of the workload.

Cracknell says the post-pandemic rush of airline work is mainly over and demand is now transitioning to its traditional seasonal busy time of October to May. In contrast, the business aviation side tends to see a fairly even flow throughout the year.

No widebody painting is available at the moment but could be considered in the future as there is currently a huge backlog of work with extended waiting times.

With so many aircraft types involved, the company outsources Part 145 support to generate Certificates of Release to Service. This is provided by Willis Aerospace at Teesside, BCT at East Midlands and Exeter Aerospace.

He says technology developments are always slow in aviation, but environmental challenges are having an effect, with chrome-free primer in widespread use and UV-cured sealants making an appearance, but use is driven by cost and availability.

As the latest facilities, Teeside reflects some of these challenges, with recirculating heating systems, improved air filtration, LED lighting (which is also better for inspection), and a dust extraction system used during sanding which directs the dust into a hopper. Unfortunately, solar panels could not be fitted due to a conflict with air traffic control.

In June 2025, the Airbourne Colours Aircraft Painting Trainee Programme was launched through a partnership with Hartlepool College and funded by the Tees Valley Mayor and Combined Authority through its Adult Skills Fund. An initial intake of 24 undertook six weeks of foundational training at Hartlepool College, to be followed by a further 19 months of training, combining paid practical and educational phases, in the Airbourne Colours facility at Teesside International Airport and Hartlepool College. Successful trainees will earn internationally recognized SAE AS7489 certification.

The company has also acquired an ATR 42 fuselage for hands-on training in the Teeside hangar, as well as lot of components.

Thanks to Brussels Airlines being a customer for ten years, the company has considerable experience of special schemes. The latest, on an A320 in March 2025, featured the Atomium, the 102-m high representation of an iron crystal that was built for the 1958 Brussels World Fair. In addition, there is an annual Tomorrowland scheme promoting the festival.

He notes that, if it takes nine days to strip and paint a 737-800, a special scheme can take twice as long, as well as being much more expensive.