Future-proofing existing fleets: how Smart Retrofits are unlocking new potential for efficiency in aeronautics

The future of aeronautics is also at stake in the fleets already in service 

For many years, airlines' strategy was based on a relatively simple principle: to gradually improve performance through fleet renewal. 

Today, this equation has changed profoundly. 

Manufacturers' order books are historically high, delivery times are getting longer and tensions on supply chains are delaying the arrival of new aircraft. At the same time, the recovery of air traffic and environmental requirements require operators to maintain high levels of availability while reducing fuel consumption and CO₂ emissions. 

In this context, one question becomes central: how to improve the performance of existing aircraft when their replacement can no longer be considered in the short term? 

The answer increasingly lies in a different approach to maintenance and engineering: Smart Retrofit. 

Existing fleets become a strategic asset 

More than 7,500 Airbus A320ceo aircraft are still in operation worldwide. Many will remain in service well beyond their initially planned service life. 

This evolution is profoundly changing the way manufacturers and airlines consider their aircraft. 

This new reality also reinforces the importance of maintenance and spare parts management. Lead times, the complexity of supply chains and the scarcity of certain components can now have a direct impact on the operation of existing fleets. 

From traditional retrofit to smart retrofit 

For a long time, retrofit operations were mainly aimed at replacing components that had reached the end of their life or had become obsolete. Today, this approach is evolving. 

Smart Retrofits leverage digital technologies to redesign certain parts or sub-assemblies to simultaneously improve their performance, manufacturability, maintainability, and availability. 

This evolution is made possible by the convergence of several innovations: 

• Digital engineering and digital twins;  
• Multiphysics simulation and structural calculations;  
• Additive manufacturing;  
• Next-generation composite materials;  
• Artificial intelligence applied to design.

The objective is not only to innovate technologically, but to respond to very concrete operational challenges: 

• Reduce device downtime  
• Improve the availability of critical parts.  
• Simplify maintenance operations  
• reduce manufacturing costs;  
• Optimize performance over the entire life cycle of the aircraft. 

Case study: a wingtip adapted to today's requirements  

The wingtip of the Airbus A320ceo is a particularly representative illustration of this approach. 

Located at the tip of the wing, this element plays a critical role in the aerodynamic performance of the Airbus A320ceo. By reducing the drag induced, it contributes directly to lower fuel consumption and CO₂ emissions. 

With the extension of the operating life of existing fleets, the need for a reliable and economical supply of spare parts is becoming a strategic issue. 

Akkodis, together with its partner pionAERO GmbH, has investigated a new way of producing this component using additive manufacturing. The goal was not to change the aerodynamic performance of the Wingtip, but to maintain its geometry while improving its manufacturability, maintainability and availability. 

The solution developed combines additive manufacturing and advanced composite materials. It is currently engaged in the aeronautical certification process. 

Beyond the component itself, this project demonstrates how digital technologies can support the gradual modernization of existing aviation platforms. 

From digital engineering to certification: transforming an innovation into an industrial solution  

In aeronautics, an innovation only becomes an industrial solution when it meets the most stringent requirements in terms of safety, reliability and certification. That's why the development of a component from additive manufacturing is not limited to its design. It is based on a complete digital chain, integrating simulation, validation and demonstration of compliance. 

Thanks to digital twins, load simulations and structural analyses, engineers can assess the mechanical behaviour of the component in its real environment at an early stage. This approach helps anticipate risks, optimize design choices, and reduce the number of physical iterations. 

In addition to saving time, this digital continuity is a major asset in preparing for future certification steps. 

In a sector where every change must be demonstrated, documented and validated, digital engineering is becoming a real accelerator of industrialization. 

Concrete benefits for airlines and maintenance players (MRO)  

While technological innovations are essential, their value is measured above all by their operational impact for operators and aircraft maintenance (MRO) players.  

The Wingtip project developed by Akkodis is a perfect illustration of this logic. 

The new design reduces assembly time from approximately 40 hours to just 6 hours, while eliminating nearly 470 rivets through the use of glue-joining technologies. 

The advantages go far beyond the scope of this single room: 

• Reduction of maintenance and downtime; 
• Simplification of manufacturing processes; 
• Improved industrial flexibility; 
• Possibility of producing spare parts on demand; 
• Reduction of inventories; 
• Reduced reliance on complex supply chains.

For airlines, these benefits represent much more than just a technical improvement. They result in better aircraft availability, lower operating costs, and the ability to operate existing fleets profitably over a longer period of time.

From innovation to industrial application 

8 For these solutions to reach their full potential, they must meet the particularly stringent requirements of the aviation industry. 

This involves comprehensive testing and validation campaigns as well as a resolutely focused orientation towards regulatory certification. Components are tested under realistic load conditions, material properties are demonstrated and all results are carefully documented. 

In the field of 3D printed aircraft structures, success does not depend solely on technical feasibility. An innovative concept can only become a scalable industrial solution if it meets traceability, security and regulatory compliance requirements. 

The combination of digital development, structural validation, physical testing and a certification strategy is therefore an essential pillar for the industrial integration of additively manufactured components in aeronautics.

The next step: rethinking aerodynamics 

While the current project is based on the existing wingtip geometry, the work is already turning to a new phase of evolution. This is precisely the aim of the European research project ECOfence, co-funded by the European Union. The work focuses on the development of new Wingtip geometries designed using CFD (Computational Fluid Dynamics) simulations assisted by artificial intelligence. 

The aim is to exploit new efficiency levers and further improve the aerodynamic performance of existing aircraft. 

The research focuses in particular on: 

• the reduction of induced drag; 
• further fuel savings; 
• further reduction of CO₂ emissions.

The project aims for additional aerodynamic gains of up to 2%. 

Thus, the challenge is no longer limited to the availability of spare parts: it is now a question of actively optimizing the performance of existing aeronautical platforms. Digital development, artificial intelligence and additive manufacturing complement each other to open up new perspectives for the evolution of fleets in service. 

Smart Retrofits: a strategic lever for more sustainable aviation  

The transformation of the aeronautics sector will not rely exclusively on the arrival of new generations of aircraft. It will depend just as much on the ability of manufacturers and airlines to make the most of the fleets already in service. 

Smart Retrofits are fully in line with this dynamic. By combining digital engineering, artificial intelligence, additive manufacturing and certification, they extend the life of aircraft while improving their operational and environmental performance.  

The Wingtip project developed by Akkodis demonstrates that it is now possible to redesign existing components in order to improve their availability, maintainability and industrial efficiency. 

The ECOfence project  opens up a new perspective: using artificial intelligence not only to optimise development processes, but also to design more efficient aerodynamic solutions. 

This development marks a profound change in the way we approach aeronautical innovation. 

Smart Retrofits are no longer just about extending the life of aircraft. They are becoming a real lever for competitiveness, enabling airlines and manufacturers to reconcile economic performance, operational excellence and environmental transition.

Editorial Note 

The Winglet project is co-financed by the European Union under the European Regional Development Fund (ERDF).