01 How to add glamour to an optimized airliner

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In this podcast Lufthansa Technik’s experts deep dive into their field of knowledge in aircraft MRO and provide exclusive insights into the design and production of parts for VIP, special mission and commercial aircraft.

In this episode, Wieland Timm will share with you how we at Lufthansa Technik add glamour to an optimized airliner. Wieland is our Vice President Sales for VIP & Special Mission Aircraft and knows the market for VIP completions like the back of his hand. In this issue he explains why it is often not an easy task to turn a standardized aircraft into a luxury good and which solutions we offer.

We at Lufthansa Technik have been completing aircraft for VIP and Government customers for over 60 years. Latest generation aircraft such as the Airbus A350 or the Dreamliner are currently in high demand among VIP operators as they provide great performance in terms of range and comfort. However, the optimized systems and vast use of composite materials for these aircraft offer fewer allowances for VIP customization. At the same time, VIP customers expect the highest level of comfort in terms of cabin functionality, connectivity and interior design. But this is only an apparent contradiction. Let me explain the six main challenges when completing a current aircraft type – and how we overcome them.

Boeing and Airbus are constantly standardizing and optimizing their products. Their aim is to be cost-efficient in production and provide an ideal balance for all major airline operations. However, this is often contradictory to what private VIP customers or government owned aircraft operators expect and require. Therefore, we have to resolve this conflict by converting an aircraft intended for commercial use in such a way that it provides the greatest possible benefits for the individual VIP or governmental operator. In general, we have to find solutions in the fields of

electrical power,

water and waste,

structural integrity,

airframe deflection,

luxury,

and entertainment. 

1st:       Electrical Power: Limited amount versus excessive need

1st: To save weight (and to reduce maintenance needs) electrical power in modern age aircraft is limited. VIP lifestyles on-board, however, require quite a lot of it. To meet this demand, we take every available source into account for the electrical power distribution system, including un- or partially- used galley feeders. To add further flexibility, we usually install a supplementary power distribution architecture. This way, we can avoid that the cabin systems breaks down, even when the self defense system is activated. Furthermore, compared to legacy airplanes where the electrical current return is run through the metal structure, composite airplanes require a dedicated network by means of wiring and metal sub-structures. In some cases, a supplementary current return network is installed.

2nd: Water and Waste: Sufficient fresh water for a 20-hour flight

2nd: Some clients ask for multiple bathrooms on board of their airplane – all of them, of course, with showers. On top of that, potable water is necessary to run air humidification for the entire cabin up to 20 hours. Such an increased water demand in the air and on the ground requires additional holding tanks to store fresh as well as wastewater. Lufthansa Technik has developed a centralized water storage and purification system which helps to avoid local water heaters and filters. This also relieves the limited available electrical power. However, this is far from easy to install. The water and waste architecture of new-age airplane is a highly integrated and IP protected CAN bus system. Interfaces to the newly installed VIP water and waste system must be thoroughly reviewed and developed.

 3rd: Structural integrity: How to bring glamour in a composite

 3rd: Compared to a metal fuselage the possibilities to attach cabin furniture and systems to a composite fuselage are rather limited. The OEM-provided pre-defined attachment points must be considered and respected in the design of the completion project. To overcome these limitations in the crown area, we have developed an attachment web structure, which interconnects the VIP cabin installations with the OEM attachment points. This allows us to install ceilings and cabin features, such as walls and stowage, which require a flexible and secure attachment. Since all our cabin installations are 3D designed and CNC manufactured, their impact on weight, resulting into structural load, is further optimized to cope with the given limitations.

 3rd: The limited stress tolerance of such optimized new-age aircraft requires a thorough review, hand-in-hand with the OEM. In this context, Lufthansa Technik has developed design solutions to meet the most critical rapid decompression requirements without compromising the interior design and functionality.

 4th: Airframe Deflection: New design principles in place

 4th: When designing an interior for a composite airplane, significant fuselage deflections need to be considered. Depending on the load case, these deflections can be 4 to 5 times higher than on metal aircraft. The installation of cabin monuments require new design principles to cope with this behavior, especially in the flex joint wing box area. We have also developed a design principle to deal with deflections of this magnitude. Adaptive furniture design is key to make sure that it stays in good shape during all flight phases. 

5th: Luxurious comfort: Amenities behind the scenes

Special attention is paid to ensure the highest level of passenger comfort. That’s why all aircraft being completed by Lufthansa Technik receive a custom-made sound insulation package to significantly lower the interior noise level. Additionally, we also offer cabin humidification systems to contribute to the overall well-being on board. This is especially valuable during ultra-long-range flights: with only 30 instead of 250 passengers on board, the air gets very dry. But VIP passengers do not only want to breathe fresh air; they also want to follow the same lifestyle they lead while on the ground. With our live cooking facilities, gym equipment, steam saunas and areal scenting systems we can offer them a splendid experience while in the air.

Special attention is paid to ensure the highest level of passenger comfort. That’s why all aircraft being completed by Lufthansa Technik receive a custom-made sound insulation package to significantly lower the interior noise level. Additionally, we also offer cabin humidification systems to contribute to the overall well-being on board. This is especially valuable during ultra-long-range flights: Luxurious comfort becomes tangible with the installation of custom-designed and highly individual cabin furniture. To meet the highest customer demands, we make use of the latest design technologies such as 3D modeling, virtual reality installation assessment and joint processes in production. All this results in a perfect fit with stunning installations. All installations have to be compliant with the latest airworthiness requirements from the EASA/ FAA and, if applicable, customer’s authority.

 6th: Entertainment: As if on ground

Last but not least: Passenger entertainment is key on ultra-long-range flights. Our 360° projection systems and screen sizes over 110 inches offer a fantastic cinematic experience. The passenger entertainment and cabin communication systems are typically interfaced with high-performance satellite communication systems to allow passengers air-to-ground calls and even streaming. Antenna installations are thoroughly reviewed and developed in close cooperation with the OEM. Remember that drilling holes into composite material is a “no go” for every OEM. To make travel as easy and comfortable as staying at home the VIP can control all functions in the cabin via apps.

Last but not least: To sum up, the latest aircraft models offer a lot of benefits for VIP operators. However, we as a completion center face quite a lot of new hurdles mainly due to the unprecedented use of composite materials. None of this is unsolvable but rather an exciting challenge.

Last but not least: Thanks for joining this episode of Lufthansa Technik’s podcast #keepyouflying. If you’d like to hear more from us don’t forget to subscribe. For more deep dives also check out our LinkedIn channel where we regularly share expert content.