Duncan Aviation is once again setting the standard for excellence in business aviation by advancing its upholstery services with innovative techniques, cutting-edge materials, and an unwavering commitment to craftsmanship. Recognizing the role that cabin comfort and aesthetics play in the overall flight experience, the company is investing in new technologies and training to ensure that every upholstery project it produces meets the highest standards of luxury and durability.
Pinpoint Accuracy and Precision
Duncan Aviation’s Engineering Team Leader Travis Smith realized how much extra time and money it took to send seat panels to outside vendors for certain specific customization processes. Because innovation is a priority for Duncan Aviation, Smith sat down with his team and researched possible ways to bring these projects in-house. After identifying potential technology and attending trade shows marketed to automotive interior manufacturers, Smith and his team found a solution.
The newest addition to the Upholstery Shop at the Duncan Aviation full-service facility in Battle Creek, Michigan, is a state-of-the-art machine that allows the shop to create perforation, multi-color sewing, and multi-color embroidery on aircraft seats and panels. The capabilities provided through the new technology and training allow better control of the design and tailoring for each individual seat with pinpoint accuracy and precision. The team is able to see on a computer screen where individual lines will hit and how the designs will look, giving them the ability to make minor alterations.
“This machine allows us to control the quality and turntimes, and lets our imaginations run wild with possible designs,” says Smith. “The designs are pretty close to endless with what we can do on quilted panels.”
Automated Technologies
Upholstery methods in particular have seen significant evolution, integrating automated technologies and the latest automated software advancements. The result is a transformation of Duncan Aviation’s upholstery processes that increases client options and allows for some truly amazing custom touches.
Upholstery automation includes machinery for the precision cutting of seat covers and foam, computerized sewing machines for stitching and quilting, and the utilization of automated design software to create seat models, optimize foam for comfort, and generate dress cover patterns tailored to customer specifications.
“The journey of automation has been like embarking on a wild roller coaster ride that’s filled with exciting highs, challenging lows, and unexpected twists and turns,” says Upholstery Automation Team Leader Nick Graham. “It involves incorporating automated technologies and processes into the design, creation, and production of upholstering aircraft cabin seating.”
The shift towards automation in Duncan Aviation’s Upholstery Shop brings several tangible benefits, such as increased consistency and repeatable design capabilities. This not only enhances the aesthetic appeal of the final products, but caters to the diverse preferences of different customers. It has sparked a transformative evolution, with increased utilization of advanced technologies to meet the demands of modern manufacturing and design.
Mixed Material Applications
Duncan Aviation has been seeing a trend toward mixing materials on aircraft seats lately, especially leather and fabric combinations. Customers love the contrast, high-end leather next to a textured fabric, and it really makes the seats pop and adds some extra comfort, too.
“This isn’t totally new for us, but demand has definitely picked up,” says Graham. “Customers want more customization and an extra touch of style, and this gives them that without adding a ton of time or cost.”
It’s not just about looks, these combinations help the seat breathe better, hold up longer in high-use spots, and give it more personality. It adds depth and makes the design feel more custom and unique.
3D Modeling for Rapid Prototyping
On the prototyping side, Duncan Aviation’s 3D printing game has leveled up, especially when working on a customer’s first article seat. The company is modeling prototype parts, printing them in-house, and testing everything before production kicks off.
“It’s a total time-saver,” says Graham. “We catch fit or design issues early, make adjustments fast, and move forward with confidence. It cuts down on rework and keeps everything moving smoothly.”
Plus, it helps us get more precise. The team is able to dial in those small details and make sure the final parts line up exactly how they’re supposed to. It’s made a big difference in how quickly and accurately we can deliver a high-quality, finished product that meets both our standards and customers’ expectations.
Major Upgrades
All three Duncan Aviation upholstery shops (in Lincoln, Nebraska; Battle Creek, Michigan;
and Provo, Utah), have seen significant transformations and improvements over the years. The most recent transformation is expansion of the Upholstery Shop in Lincoln. It is designed to enhance the efficiency of the seat reupholstering processes. This includes a new humidor room and specialized leather racks for storage, adjustable tables facilitating optimal disassembly and reassembly of aircraft cabin seating, mobile seat storage, a dedicated area for leather and seat inspections, a new paint booth, and upgraded CNC machines.
Additionally, the upholstery processes have taken a significant step forward with the introduction of a 5-Axis CNC machine. This machine has transformed processes by facilitating intricate and precise cutting and shaping of cabin seat foam. The incorporation of the 5-Axis machine has led to heightened consistency in both cabin seat foam and dress covers. The machine’s versatility enables Duncan Aviation to craft complex and customized designs with accuracy, ensuring a higher standard of quality in upholstered products.
These improvements aid in creating high-quality seat products that maintain their appearance. These developments stand as clear indicators of Duncan Aviation’s Upholstery Shop’s firm dedication to fostering innovation.
Redefining What’s Possible
With a steadfast commitment to innovation, craftsmanship, and customer satisfaction, Duncan Aviation continues to elevate the standard for aircraft upholstery services. From adopting state-of-the-art machinery and automated design technologies to expanding facilities and embracing creative material combinations, the MRO is redefining what is possible in cabin comfort and aesthetics. These advancements not only enhance the visual appeal and durability of seating solutions but also reinforce Duncan Aviation’s position as a leader in the business aviation industry—where precision, quality, and personalization take flight.