Story ID: 025
Completions: Highlighting the Best and the Latest
By: James Wynbrandt
Caption: Completions shops showcase their latest projects
Word Count: 3641
Demand for completions and refurbishment (C&R) is booming, according to more than a dozen companies across the industry that service aircraft from turboprops to executive airliners, with growth projected to continue. Research & Markets estimates global aviation C&R spend will rise some 36% between 2026 and 2034, and both the business jets and VIP refurbishment segments account for “significant market share.”
Several factors are driving this growth, and clear trends are emerging. Key among them is roaring low-earth-orbit (LEO) satcom installation activity. “New internet options have pushed retrofit work,” Duncan Aviation reported, specifically, LEO satcom availability.
Greenpoint Technologies said it is putting “a strong focus on integrating next-generation LEO connectivity systems” in current projects, and multiple providers noted recent Starlink installations, even as new LEO network options come online. Lufthansa Technik (LHT) recently installed Gogo’s Galileo LEO, leveraging Eutelsat OneWeb’s network, on a VIP ACJ319neo completion.
At the same time, the widebody market is “very, very busy right now,” LHT said. Greenpoint Technologies estimates 10 widebodies—ACJ350s and BBJ787s—entered completion in the second quarter alone, “testing industry capacity, [and] prompting many clients to move quickly to secure production slots.”
AMAC Aerospace sees “a clear market shift toward next-generation widebody platforms,” specifically ACJ350s and the forthcoming BBJ777X. Cabin concepts for the latter have been presented by LHT, Greenpoint, and Jet Aviation.
As for trends with widebodies, VIP and VVIP customers are showing less appetite for bespoke completions, and providers are offering more modular cabin options. Boeing Business Jets’ BBJ Select program, LHT’s BOW narrowbody concept, Greenpoint Technologies’ AeroSuite pods, and the Comlux/ACJ TwoTwenty interiors are examples. “Even in the VVIP markets, cost of ownership and an eye on resale value are driving a shift to standardized, less unique interiors,” said Comlux.
To keep up with this demand, C&R companies are instituting formal apprenticeship programs to meet hiring needs. Comlux America is partnering with the state of Indiana, developing programs with local colleges “to funnel more people into the industry.” Pennsylvania’s SureFlight Aircraft Completions apprentices students from local vocational schools; their work during school hours is graded, and “some graduate and come on full-time.”
Ohio’s Flexjet has brought its fleet refurbishments in-house and, in tandem, created an intensive training program. “Almost all our talent is being developed in-house now,” the company said.
Meanwhile, C&R companies are finding additional help: providers report putting AI to work across multiple disciplines. It creates multimedia presentations and analyzes complex test data; AI screening tools assess job candidates. Customers use AI tools to develop aircraft paint schemes, though “just because it looks good in AI doesn’t mean that it’s reasonable for an aircraft,” one provider noted. But for now, AI “does not have a role in the physical production of aircraft,” as LHT said and others echoed.
This report highlights recent developments from the companies whose work helps set the standards for C&R today and showcases a recent project from each, demonstrating the artistry and technical capabilities deployed on these refurbishments and completions. These interiors and exteriors also illustrate the trends and customer preferences driving industry growth.
Aftermarket Refurbishment and MRO ProvidersDuncan Aviation—Lincoln, Nebraska
With its Provo, Utah full-service facility now completely operational, Duncan Aviation’s business has been “very brisk over the last year,” marked by growth of large-cabin customers operating G550s, Global Expresses, 7Xs, and Bombardier Challengers.
A recent Challenger 350 interior and exterior refurbishment performed in Provo captured the clean, modern aesthetic the longtime owner sought, balancing dark veneer and carpeting with white soft goods and paneling for a clean, cohesive interior. Redesigned two-tone leather seats and a single-tone leather divan feature perforated inserts and contrasting black French stitching. The custom black carpet was owner-inspected and approved before being tip-sheared to reveal its full white-wave pattern.
The interior refresh included elements commonly requested in upgrades across the industry today, said senior completions rep Jeff Beaudette: custom RGB lighting, home-theater quality audio system, and modern vinyl to replace carpeting in entryways, galley, and lavatories.
“Carpet is on the outs,” said Beaudette, in favor of new textures and colors of rolled vinyl and LVT luxury vinyl tile, “for cleanability, and because it doesn’t degrade when it gets wet.”
The new livery features a pearl tricot base in sweeping white arcs overlaid by swaths and stripes of light and dark grays, creating the appearance of an aircraft in perpetual motion.
Global Aircraft Interiors—Ronkonkoma, New York
Global Aircraft Interiors’ clients—midsize and large-cabin jet owners—comprise both Part 135 charter and private Part 91 operators, and refurbishments reflect their respective use. “There’s a lot more wear and tear on a charter aircraft,” said Robert Roth, president and owner.
Global’s 45,000-sq-ft MRO facility can accommodate four Gulfstreams simultaneously, and has been “very, very busy” with both types of upgrades over the past year, he said.
The recent interior refurbishment of a Part 91-flown Falcon 2000 showcased the firm’s bespoke cabin approach, featuring new seating and redesigned interior dressed in updated neutral colors, anchored by two-tone gray Corian surfaces, and complementary carpeting. Subtle orange welting accents the dado panels. Veneers were retained, darkened, and refinished with high-gloss clearcoat. In the galley, solid-surface countertops replaced brittle, aged stone. The cabin was enhanced with RGB lighting and theater-quality audio systems.
For charter aircraft interiors, leather “has to be high-grade, but durable,” Roth said. Wood finishes should be gloss: “Scratches can be wet-sanded and polished out.” Carpets have to stand up to washings, and soft goods materials must be easy to clean on the road. “If you have a Part 91 aircraft, it’s going back to the hangar,” he noted.
Elliott Aviation—Moline, Illinois
Full-service MRO Elliott Aviation “develops solutions that go above and beyond refurbishment” for aircraft ranging from Beechcraft King Airs to midsize jets, said Meghan Welch, director of paint and interior sales. The recent interior and exterior transformation of a Cessna Citation Sovereign put those practices on display.
In the cabin, blue custom-patterned carpet anchors the white interior and contrasting dark cabinetry, while quilted seats add character and texture. A galley upgrade, new audio system, and Starlink installation were included. Constellations can be displayed on the headliner via custom Prizm LED lighting, created at the client’s request. And “every door and drawer is purposed to maximize the space in the aircraft,” said Welch.
The Sovereign’s new livery features sweeping grey and black swaths with gold and silver highlights over a bold white base, applied in Elliott’s computerized, downdraft paint booth. “Demand for paint is very, very strong right now,” Welch said, with many customers “looking for more color and personality.” A Kodiak owner recently had P-40-style shark’s teeth painted on his cowl.
Known for Garmin G5000 avionics upgrades for the Citation XLS, Elliott now offers Citation Excellence, an all-inclusive package combining the G5000 retrofit, interior refurbishment, and new paint, creating “a like-new airplane while eliminating obsolescence issues.”
SureFlight Aircraft Completions—Coatesville, Pennsylvania
SureFlight Aircraft Completions serves turboprop, rotorcraft, and light and midsize jet operators. “A lot of our customers are owner pilots, so we’re more of a custom shop,” interior completions manager Dave Thompson said. Standard cabin refurbishments incorporate new carpeting, cabinetry, upholstery, soft goods, and seat design, and projects often include new paint and avionics upgrades. Renderings for an upcoming PC-12 refurb showcase current design preferences, with white leather seats, contrasting black Alcantara sidewalls, and forged carbon-fiber cabinetry.
SureFlight opened as a paint shop for Sikorsky helicopters in 2009, and comfort with livery is displayed in the red and black honeycomb scheme applied on a Pilatus PC-12 during a recent refurbishment.
Last year, the company opened a facility in Springville, Utah, to support its growth. In addition to Citations and Beechjets, it’s known for work on carbon-fiber Beechcraft Premier jets.
Customization notwithstanding, SureFlight recently added generic interior panels and seat covers from Generation Global to its refurb options. “If [customers] just want something standard, or back to original OEM, we have the capability of saving them a few dollars,” Thompson said.
International Jet Interiors—Ronkonkoma, New York
“It’s not just how an aircraft should look, but how it must perform, endure, and live at altitude,” said International Jet Interiors (IJI) president Eric Roth, explaining his approach to working on clients’ Gulfstreams, Bombardiers, Dassault Falcons, and BBJs. A recent Gulfstream G550 interior refurbishment embodied the principles in application. Combining utility and artistry, a 42-inch monitor rises from the mid-cabin credenza. Handcrafted tables incorporate leather inlays, while the earth tones and textures, curves and contours, and natural-finish wood veneer bulkheads harmonize the interior, creating a warm, tranquil sanctuary.
Celebrating its 40th anniversary this year, IJI performs all work in-house. Facilities include a design studio with scale Gulfstream and Falcon mockups, and full engineering, cabinetry, and upholstery shops, in addition to its hangar and paint booth.
Roth sees “a shift toward fully realized environments” as customers “accessorize and personalize the entire aircraft.” IJI is addressing the trend with Jet Essentials, its in-flight accessories and cabin-ware outfitting service for “life at altitude.”
Created in collaboration with Italian luxury brand Sferra, the collection includes custom-tailored table linens, oversized cashmere blankets, plush pillows and slippers, and other coveted cabin items, designed with aircraft proportion, weight, and in-flight performance in mind. “What works on the ground doesn’t always function at 40,000 feet,” Roth said.
VIP Completions—Fort Lauderdale, Florida
Many of the refurbishments that VIP Completions performs on large-cabin business jets are referrals from sister brokerage SmartJets. With scarce late-model inventory available, SmartJets locates suitable airframes, and VIP can quote an all-inclusive refurbishment price, providing significant savings over market value.
“That’s where the value proposition is for our customers,” said VIP president Ben Shirazi, who founded both companies in 2013. VIP’s clients “expect to have all the creature comforts they do in a new home.” Home theater audio systems and RGB lighting are de rigueur.
A recent Gulfstream 550 project, created with design firm Yodezeen, the Gulfstream owner’s residential architect, exemplifies contemporary, elegant minimalism and won the 2026 Yacht & Aviation Award for Best interior design-business jet/VIP completion. Using an earthtone palette, the cabin is outfitted with materials including Garrett leathers, Loro Piana cashmere, custom Italian hand-tufted carpet, eucalyptus paneling, and carbon-fiber accents. Custom dynamic fiber-optic lights create starlight patterns in the headliner.
Upgraded galleys are a “big piece” of current refurbs, Shirazi said. Customers “are making cocktails for their clients, like a house bar.” All cabinetry, upholstery, and work besides plating is performed at VIP’s 35,000-sq-ft production center, critical “for controlling project timelines,” he said.
Flexjet—Cleveland
Fractional share provider Flexjet operates almost 400 jets, all tastefully appointed, including limited-edition LXi Cabin models, which encompass more than 50 unique designs. “We are the antithesis of the beige and grey interior,” said Jay Heublein, Flexjet Technical Services president. Flexjet’s Riva Volare cabin, for example, features “Blu Sera” leather, aquamarine piping, blue and white maritime stripes, and mahogany and maple trim. But the fleet requires ongoing refurbishment, a massive undertaking.
Three years ago, Flexjet began bringing all MRO in-house and expanding capacity, borrowing techniques from the high-end automotive and marine industries. “We went from 85% outsourcing to 99% in-house, and from 120 maintenance employees to more than 1,600,” Heublein said.
A G650 refurbishment that took 10 to 12 months now takes eight to 10 weeks. As for fit and finish: “I guarantee you couldn’t tell anything’s different,” he said.
Addressing the skilled labor shortage, the company’s apprentice program uses technology “to jump what used to be 10 or 15 years of hands-on sweat and tears.”
To control spiking parts costs, Flexjet, a Directional Aviation company, is also in-sourcing replacement parts. “My engineering team is working on PMA reverse engineering the carbon brakes for every one of the airplanes we operate,” Heublein said.
Executive Airliner Completion and MRO SpecialistsAMAC Aerospace—Basel, Switzerland
AMAC Aerospace creates “highly personalized residential-style environments,” reflected in a recent Airbus VIP ACJ320 completion. The furnishings’ neutral tones, popular in many contemporary interiors, are offset by rich wood veneers, while curved surfaces and orange accents emphasize the layout’s natural flow. Unseen is the LED lighting and cabin controls discreetly integrated in the interior.
The market for VVIP refurbishments, modifications, and cabin upgrades “is characterized by constant demand and strong growth, and slot availability is under constant pressure,” said group sales director Eric Hoegen. Narrowbody C&R inductions remain robust, and “a significant number of advanced negotiations are underway.”
In December, AMAC delivered the first head-of-state (VVIP) ACJ350 completion.
Regionally, AMAC sees demand in Europe for refurbishments and life cycle extensions. Strong Middle East activity is driven by governmental and VVIP operators. In North America, modernization and reconfiguration projects dominate, while Asia-Pacific activity is expanding.
Last year, AMAC added engineering firm Kreative Engineering Services to its portfolio and is now upgrading its headquarters engineering facility.
Lufthansa Technik—Hamburg, Germany
Lufthansa Technik’s “BOW” narrowbody VIP cabin concept, created with BMW Designworks and unveiled in March, envisions a modular solution for group VIP travel—a board of directors, professional sports team, touring band, or delegation. “This is a new customer segment,” said Fabian Nagel, v-p of sales for VIP and special aircraft services.
Named for the design’s signature arcs and soft shapes, interior components can be chosen and installed per the client’s needs, and when in service, changed during maintenance events. Two-passenger BOW Suites with convertible full-flat beds feature individual inflight entertainment system (IFE), cabin managment system (CMS), and environmental systems.
LHT's Hidden Touch controls won the Red Dot award for Design Concept 2025. Table surfaces in the lounge incorporate LHT’s new intelli-table haptic technology, which blends a disappearing high-definition touchscreen directly into durable hard surfaces that can resemble wood, carbon fiber, metal, or other materials. A central lounge table morphs from one into four individual surfaces.
Similarly, LHT’s latest Nice CMS iteration, which debuted on the Embraer Praetor 500E and 600E, incorporates an OLED multifunction “Smart Window” that can function as a window, fed by three external cameras.
LHT has also introduced a modular VIP cabin upgrade package for aging Airbus ACJ318 Elites; some 25 were built between 2007 and 2015, and originally outfitted by LHT.
Meanwhile, prospective BBJ777X customers “are waiting for the jet to enter service commercially before committing” to buy, Nagel said. LHT unveiled its CelestialStar cabin concept for the aircraft in 2023.
Jet Aviation—Basel, Switzerland
“Demand for large-cabin and widebody completions continues to grow,” said Christoph Fondalinski, v-p of completions at Jet Aviation. For the company’s clients, “Comfort, connectivity, usability, and overall passenger experience” are the top priorities. Highly customized and completely bespoke projects remain the standard.
The Hesperis interior concept from its design studio sees the narrowbody cabin as a calm and minimal “sanctuary of well-being.” Lightweight bulkheads integrating 3D-printed panels embody a focus on optimized form and function. Composite seat shells reduce weight and volume, and “finishes become structure, simplifying the space and reducing visual and physical complexity.” Production-wise, advanced 3D manufacturing enables a more fluid, seamless interior, with materials that incorporate natural tactile qualities.
This year, Jet Aviation installed the first IFX system, its in-house developed IFE/CMS, as part of a narrowbody refurbishment. The unit is backward-compatible and supports simple component updates and change-outs. Fondalinski noted that refurbishment customers are “prioritizing integrated solutions to combine maintenance, cabin upgrades, connectivity, and paint within a single input.”
Looking ahead, the company foresees “stable and diversified demand for completions and refurbishment services across all major regions.” Meanwhile, in Basel, the completions specialist is preparing to open the first of two widebody hangars undergoing extensions and refurbishments of their own.
 Greenpoint Technologies—Bothell, Washington
Amid “a notable surge in widebody activity,” Greenpoint Technologies delivered this year its ninth BBJ787 Dreamliner (a -9 model, coincidentally). Greenpoint created a “calm, residential environment through layered materials, soft forms, and integrated lighting,” said v-p of sales and design Bret Neely. Though confidentiality agreements preclude showing the VVIP interior, images of a recent 787 completion illustrate a similar aesthetic.
Large-cabin VVIP customers today want “privacy and flexibility” within the aircraft, making Greenpoint’s AeroSuite— a modular private bedroom and personal lounge—a popular outfitting option. Six were installed aboard the most recent 787 completion.
Greenpoint has also partnered with Boeing Business Jets and Aloft AeroArchitects on the BBJ Select program, offering catalog-selected interior designs and quick delivery times on BBJ Max 7 and Max 8 models. Greenpoint provides the program’s engineering services.
Concurrently, the company is expanding its aftermarket maintenance, modification, and upgrade services and has tripled its client support team over the past year.
Anticipating the forthcoming BBBJ777X, in 2023, Greenpoint unveiled its Zen cabin concept for the jet. The Triple 7, and the interior, have drawn “continued interest from prospective clients,” said Neely, and the jet “has the potential to become a preferred choice for next-generation VIP and head-of-state aircraft.”
Comlux America—Indianapolis
Comlux America, the completions and MRO division of Switzerland’s Comlux Group, sees “a shift in the market by customers to a more standardized, but still bespoke, product,” said CEO Adam White. Clients who traditionally sought “very high-end [completions], now want less complexity.” He acknowledged that Comlux, which performed the first BBJ Max completion, is known for technical innovation. “Controlling things through your phone seemed unique and novel,” White said. “Now, customers just want a switch next to the light.” Government and head-of-state refurbishment projects are also choosing standardized interiors, he said.
Comlux’s ACJ TwoTwenty, its partnership with Airbus Corporate Jets, creates cabins from pre-engineered components, providing dozens of configurations and several design style choices, saving significant amounts of time and money over a custom completion, and epitomizes the shift. Production is accelerating; four TwoTwenties have been delivered, and the target is four to six per year.
Comlux will also outfit a VIP fleet (six Airbus A220s and two A321s) in standard formats for Magnifica Air’s forthcoming luxury airline service, slated for a 2027 debut. Carrying between 45 and 54 passengers, the cabins will offer private suites.
Comlux facilities now occupy some 250,000 sq ft, with room for further expansion. Last September, private equity firm Everpeak Capital Group made “a strategic investment” in Comlux America.
Bizliner/VIP OEMs Airbus Corporate Jets—Toulouse, France
Airbus Corporate Jets (ACJ) sees a market for new luxury “shuttle services,” president Chadi Saade said, citing hotel chains, sports teams, and companies that transfer their staff. An interior design sketch of an ACJ220 in shuttle configuration reflects “the trend we’re seeing now,” which is also “very much appreciated by a lot of presidential and government customers,” he said.
The layout includes a forward “presidential” command suite (equipped with “therapeutic lighting” and sidewall-embedded augmented reality screens), a negotiating lounge, a meeting room, seating for a VIP delegation, and a medevac unit. Medevac demand is strong, Saade noted, and units have been certified for most ACJ models.
ACJ’s completions are performed at five authorized completion centers. ACJ has delivered 85 turnkey projects itself via the facilities, but “because of demand in the overall market, we want to add at least one more outfitter to our network,” Saade said. “We’d prefer it to be in the United States.”
Saade noted that the composite airframe of its widebody ACJ350 is outfitted with ACJ’s Easyfit pre-installed brackets, attachment points, and system interfaces, simplifying completions.
Meanwhile, ACJ has launched ACJ Connect Link, a OneWeb LEO connectivity offering, and has expanded its service center network, adding Bodrum, Turkey, in partnership with AMAC Aerospace last November.
Boeing Business Jets—Renton, Washington
Boeing Business Jets’ BBJ Select program offers modular lounge, suite, galley, and other cabin outfitting options for the BBJ Max, providing some “200 different combinations, at a significantly lower price and in less time” than a custom completion, said global marketing director Chris Shindle.
Launched for the BBJ Max 7 in 2023, the recent addition of the Max 8 has “accelerated discussions…both from ultra-high-net-worth individuals and individuals comfortable with having an off-the-shelf catalog option,” Shindle said. Purchase will come with a residual value guarantee, providing buyers with “financial confidence.”
Boeing has partnered with Greenpoint Technologies and Aloft AeroArchitects on the completions, to be performed at Aloft’s Georgetown, Delaware facility.
Orders continue for green BBJ737s (Max 7, 8, 9), which come with low cabin altitudes and humidification systems like the 787s.
BBJ announced its Queen of the Skies offering—turnkey refurbished BBJ 747-8s in VIP and VVIP configurations—in late 2025. “It’s a very small market, but big enough to launch a program,” Shindle said. BBJ is in discussions with prospects and “carriers that have this feedstock.”
Concurrently, the BBJ787-8 model, providing excellent range and high/hot performance, has been particularly popular in Asia. A recent production increase at Boeing’s North Charleston, South Carolina Dreamliner factory should increase availability.
Meanwhile, though the BBJ777X won’t enter service until the early 2030s, given the lead times for such projects, discussions with prospects are proceeding.