Cabin completions
A home away from home
Business jets are all about efficiency, ease and luxury. But what does it really take to make them feel as luxurious as a floating home in the sky? Words: Yuvan Kumar
Movies, fine dining & more
Airbus ACJ TwoTwenty
Top cabin completions enable principals and their guests to enjoy the height of airborne luxury from movie nights to fine dining and more. The ACJ TwoTwenty offers six zones with a floor space of 786sq ft (73sq m).
Cabin completions
A home away from home
Business jets are all about efficiency, ease and luxury. But what does it really take to make them feel as luxurious as a floating home in the sky? Words: Yuvan Kumar
Movies, fine dining & more
Airbus ACJ TwoTwenty
Top cabin completions enable principals and their guests to enjoy the height of airborne luxury from movie nights to fine dining and more. The ACJ TwoTwenty offers six zones with a floor space of 786sq ft (73sq m).
▼ Award-winning designs
Airbus A320-A350 range
Lufthansa Technik has delivered about 150 completions mainly on the Airbus A320-A350 range and Boeing’s 737-747 range. This Nature’s Touch cabin won a Reddot 2019 design award.
IT STARTS WITH a blank canvas; a bare slate offering endless possibilities. That is the transformative power at the fingertips of interior designers and completions teams. Think of all the VVIP business jet interiors you have ever seen. They all started like this – as green aircraft fresh from the manufacturer. Then, through a process of design and deliberation, the cabin’s contents are sourced, assembled and laid out. Understanding the client’s every need, the completion centre or OEM will tailor the aesthetic to include the smallest details.
According to Sylvain Mariat, head of creative design at Airbus Corporate Jets, the first step to designing a cabin is about thinking about the future life onboard. “In the interior design process, ‘space planning is first’. Space planning includes blocking out interior spatial areas, defining circulation patterns and developing plans for furniture layout and equipment placement,” Mariat tells Corporate Jet Investor.
Understanding the client’s desired aesthetic and atmosphere are crucial to creating a concept for the space. Mariat says successful projects often hinge on professional turned personal relationships. “They are formed early on and are nourished by clear communication and mutually understood expectations.”
CEO of jet completion and refurbishment company Camber Aviation, Tom Chatfield agrees. Whether it works with private individuals or businesses, his company operates very closely with clients. The time invested depends on which aircraft they have and their design requirements. “The more time we invest at the beginning of the project understanding what the client wants, the more successful the project will be,” he tells Corporate Jet Investor.
This process of working with the client involves a great focus on materials and construction. Mariat says quality is key. “Good quality materials have a sound and a feeling that’s different than poor quality materials. It is very important as a VVIP cabin designer to combine different materials, shapes, patterns, and textures. These differences can enhance their innate properties,” he says.
▼ Bathroom in the sky: This palatial design, from Unique Aircraft, was intended for a BBJ 777X jet.
Image courtesy of Unique Aircraft and ACA 3D
Almost all cabin interior designers will tell you the most successful designs are those which combine aesthetics and quality while meeting the client’s needs.
Camber’s Chatfield says: “We invest significant time with our clients so that we truly understand what they are seeking, before we begin to work with a designer to define the initial cabin layout plan, sketches and cabin capabilities.”
Companies like Camber will work very closely with clients to develop and refine the cabin until they are in 100% agreement with the specification. “That being the case, we can focus on transforming this vision into the incredible aircraft that they are seeking,” adds Chatfield.
This is how Camber completed 39 projects, including outfitting and refurbishing large business aircraft ranging from Bombardier Challengers and Dassault Falcons to Airbus and Boeing narrow- and wide-body aircraft.
Mariat adds to this, saying aspects of customer perception of aesthetics, quality, personal space and safety are some essential points.
Also it’s important to take into account physical aspects such as vibration and sound transmission, heating and air-conditioning, odour control and ventilation, artificial and natural lighting. Spatial aspects such as circulation and access, seating arrangements and the ergonomics of customers' sitting, sleeping and storage requirements are crucial too.
“When you understand all elements to resolve this complex design equation, you are on the way to delivering the best cabin ever,” he adds.
For clients of Saudi Arabia-based aircraft management and completions company NasJet aesthetics such as colour specifications can be very important. Yosef Hafiz, vice president, Sales and Marketing, tells CJI : “Making sure what was agreed in the specifications selected by the owner and that his colour board and paint scheme match the aircraft are vital. When selecting interior colour, the principal does not get a chance to see how they blend in all together in a complete cabin till the very end of the project,” says Hafiz.
“Connections and word of mouth” have been a crucial piece in the 35 completions done by NasJet.
Eric Gillespie, executive vice chairman of Canada-based maintenance and completions company, Flying Colours Corp, tells CJI each conversion has a unique set of requirements. Private aircraft owners increasingly request interiors like those in a residence, yacht or car. “Aviation regulations require specific standards, so it is not always possible to transfer the exact design straight to the cabin, so we have to manage the owner’s expectations,” says Gillespie.
“Our main challenge is managing customer expectations to ensure that they understand what can be done within the time and budget allocated. Our expert team is well versed in the process so can anticipate any issues before they even arise.”
Sometimes clients request custom products. “The first task for making the vision a reality is to confirm if the airframe infrastructure needs modifying,” says Gillespie. The product would then be tested for functionality and flammability. “Subsequent tasks will relate to certification and generating a supplemental type certificate for any item that has not been equipped previously into the airframe.”
How long does it take to deliver a cabin completion project?
DARON DRYER, CEO of Comlux Completions, which will be completing the first six interiors of Airbus’s new ACJ TwoTwenty, supplies the first answer. It will take about 12 months to finalise interiors for the first aircraft, which will be a demonstrator, he tells CJI.
“The goal is to start producing aircraft with a down time of eight months, moving to six months as we become more and more efficient,” he says. There are over 100 permutations and combinations you can create with the TwoTwenty’s interiors.
Depending on the exact specification and mission requirements, Flying Colours Corp’s Eric Gillespie says: “A light aircraft could take six weeks while an ultra-long, large cabin could take up to five months.”
Younger pre-owned aircraft may only need touch ups, some leather work repairs and new flooring, says Gillespie. “Invariably paint work is required whether the frame is old or new.”
Flying Colours provides a wide range of services including avionics, paint and services under one roof. This means it can run different elements of the completion process in parallel, says Gillespie.
Flying Colours craftsmen are pictured at its Singapore facility. Large cabin conversion could take up to five months, says its Eric Gillespie.
Airbus’s head of creative design, Sylvain Mariat says: “The ratio to design a wide-body in comparison to designing a single-aisle aircraft is probably around four times longer if we are talking about the same level of elegance for both planes.” Mariat adds that factors influencing time to complete interiors are layout, the complexity of the design and the level of elegance,
“For pre-owned aircraft, it depends on the level of change. Sometimes, it is just a carpet change, or it could be an entire cabin change, from top to floor,” says Mariat.
For Camber Aviation’s CEO Tom Chatfield: “Outfitting a new or green aircraft is highly dependent on the lead-time given to complete the design and engineering, to contract the completion centre and suppliers, as well as begin fabrication of key long-lead cabin components such as seats and monuments.”
With an eight-month lead-time for an ACJ or BBJ narrow-body completion, it will take 12-14 months to deliver. Whereas for a wide-body aircraft, a 12-month lead-time before aircraft arrival takes about 24 months to complete.
Chatfield echoes the other experts: “The actual time will depend on the complexity of the design; the systems being installed and the skill and experience that the completion centre has on that particular aircraft type.”
NasJet’s vice president, Sales and Marketing, Yosef Hafiz says: “Generally, once an aircraft is delivered green and the Certificate of Airworthiness is issued, it takes between three to five months to complete depending on how complex the interior design is. Larger cabins have more can last between 12 to 18 months.”
▼ VVIP insight
Boeing BBJ 737-700
This striking interior design, from Citadel, was informed by the company founder’s personal insights of big business jet completions. Before launching Citadel, he was the private owner of several VIP/VVIP aircraft and the company bases its designs on his experiences as a completions customer.
CEO of Comlux Completions, Daron Dryer, says no requests are unfeasible as long as the airframe is approved to keep flying. “You could do anything from recovery to upgrades and reorganisation to a complete modification. What we see the most obviously is the upgrades in communication and entertainment equipment,” says Dryer.
It’s best to couple with a large maintenance check so it is less invasive, he adds.
According to Ian Douglass, program & technical account manager, Business Aviation at Viasat, connectivity systems have varying levels of integration with different cabin interiors. “For example, Ka- or Ku-band can integrate with the aircraft CMS [cabin management system] for additional features, controls, etc. enabled by discrete wiring supported through our terminal configuration. Another example might be using connectivity (i.e. Ka-band) for streaming to a cabin monitor via Apple TV, Roku or other carry-on devices. There are varying levels of integration and technical requirements that result in a more complex or basic implementation,” Douglass tells CJI.
The process of installation largely remains the same for pre-owned jets. Douglass says: “Many of our Ku installs – and Ka to a degree – are aftermarket completions. Typically, it is a lighter integration with cabin systems/CMS but still highly capable. Viasat is rolling out tools and applications that will vastly improve cabin controls and utilities without heavy duty discrete development.”
OEMs have authorised retailers who can sell and perform installs. They provide all the training and documentation to support that. Viasat also routinely conducts training and refresher activities with relevant teams.
The biggest challenge with fitting connectivity into a completions project is getting requirements and executing development efforts specific to each project. “Viasat is always working on ways to harmonise this with more dynamic configurations and refining implementations,” he says.
Connectivity and lighting company Spectrum Networks is pioneering the use of LiFi [light fidelity] technology – wireless network through lights – to keep devices connected in the cabin. In addition, the company’s far-UVC light technology will help keep cabins sanitised at all times.
CEO Jay McGrath tells CJI these will simply replace existing cabin lamps on commercial and business aircraft when aircraft are down for maintenance.
When a client purchases a pre-owned aircraft, the most common things they tend to change are the carpet, exterior paint, or veneer. They will also work on the leather on the seats, dado panels, and updating the aircraft with high-speed internet, if it is not already installed, according to NasJet’s Hafiz.
This executive lounge for the Airbus ACJ320neo is from Comlux.
“What we see the most obviously is the upgrades in communication and entertainment equipment.”
Daron Dryer, Comlux Completions
▼ Just add colour courtesy of Mr Colourful. This ACJ TwoTwenty cabin features the distinctive artwork of Cyril Kongo.
Floored by design: F/List says its Syntec flooring system is the only vinyl tile flooring concept in the industry.
Sustainability in the cabin
Both Chatfield and Mariat underscore the shift towards sustainability in the cabin. Whether it is for cabins designed from scratch, or ones that are brought in for refurbishment, owners and operators are looking at using more environmentally sensitive finishes and processes.
Chatfield says: “In the case of refurnishing an aircraft cabin, wherever possible, we look at repurposing as much of the old interior as possible – for example, reusing passenger seat frames instead of replacing. Instead of replacing veneers with rase woods, we often recommend decorative film applications that are attractive, robust and cost significantly less, while making a much lighter impact on the environment, when compared with traditional re-veneering.”
Mariat supports this, saying designers are now embracing a “life-cycle approach” when selecting materials for use in new and renovated interior spaces. “In ACJ design studio, we are taking care of the long-term impact of materials. Using sustainable materials will lower the environmental impact caused by various materials and substances,” says Mariat.
It is important to consider both direct and indirect impacts throughout all phases of production process. That includes the use and future removal and disposal of construction materials and supplies.
While awareness of the need to use sustainable materials is becoming more common, the materials themselves are harder to come by, says Eric Gillespie, executive vice president, Flying Colours Corp. “We are beginning to have conversations around sustainability. However, there are still a limited number of sustainable products on the market available and our main guidance is to work with products that meet the required aviation standards.”
Mélanie Prince, head of innovation, of luxury interior manufacturer F/LIST, agrees with Gillespie. “Customers are still very hesitant to compromise on weight, cost, and performance for eco friendliness,” says Prince. This is why the company has come up with its own product portfolio to show sustainable options can “perform adequately and even look better than their conventional counterparts”.
Through a joint venture called Hilitech, which applies lightweight carbon monocoque technology similar to Formula 1 racing, Prince says F/LIST has seen 30% reductions in weight. The company has also used agricultural residuals and industrial leftovers to create decorative materials based on materials from fruit fibre and by-products of its stone-machining department.
Price says F/LIST’s Syntec flooring system is the only vinyl tile flooring concept in the industry. “It eliminates the problems associated with vinyl rolls enabling OEMs, owners and designers to create unlimited, bespoke floor design concepts. That enables the use of individual rectangular or square tiles, or a combination of both.”
Comlux’s Dryer is an advocate for sustainability options in the newly released ACJ TwoTwenty. He says you can have reconstituted veneers, “so you don't have to take new trees down, it can be reclaimed, reconstituted”. Also available is natural fibre carpeting that includes processes that have lower waste, less chemical and faster processing times, according to Dryer. The first ACJ TwoTwenty will be delivered to Comlux.
Some completions teams have a hybrid approach. Take Lufthansa Technik’s ‘Nature’s Touch’ design – a combination of Eastern and Western cultural elements – for a narrow-body aircraft, for example.
Wieland Timm, vice president, Sales VIP & Special Mission Aircraft, Lufthansa Technik, tells CJI: “Nature’s Touch created a symbiosis of nature, technology and human demands. Textile, subtle stripes simulating bamboo wood grain are complemented by natural materials such as marble, genuine leather, wool and silk.”
Nature’s Touch is one of 150 completions done by Lufthansa Technik. These have been aircraft in the Airbus A320-A350 family and Boeing 737-747 range.
Airbus’s Mariat says the details in cabin interiors are extremely vital. “The sweeping strokes of an interior design concept are nothing without the supporting details. A good designer must be detail-oriented,” he says.
Airbus teamed up with French graffiti artist Cyril Kongo, also known as Mr Colourful, to turn each cabin into “a flying contemporary art gallery”, with original designs for each client. The main lounge will be partly hand-painted by Kongo.
Mariat says to further aid the feeling of the home in the sky, he tries to incorporate the client’s everyday belongings into the design. And finally, it is necessary to evaluate an area’s overall composition for balance.
“We can do it by finding a balance starting with the room’s architectural features, like window panels and doors, and then adding in pieces until equilibrium is found,” adds Mariat.
So, there really is next to nothing one cannot do when it comes to cabin interiors. Camber’s Chatfield summed it up perfectly: “There are limits on what can be done to a private jet cabin, but many features can be certified if the client retains a good designer, completion manager and completion centre. Why settle for a ’stock’ cabin when tailored is possible?”
Floored by design: F/List says its Syntec flooring system is the only vinyl tile flooring concept in the industry.
Sustainability in the cabin
Both Chatfield and Mariat underscore the shift towards sustainability in the cabin. Whether it is for cabins designed from scratch, or ones that are brought in for refurbishment, owners and operators are looking at using more environmentally sensitive finishes and processes.
Chatfield says: “In the case of refurnishing an aircraft cabin, wherever possible, we look at repurposing as much of the old interior as possible – for example, reusing passenger seat frames instead of replacing. Instead of replacing veneers with rase woods, we often recommend decorative film applications that are attractive, robust and cost significantly less, while making a much lighter impact on the environment, when compared with traditional re-veneering.”
Mariat supports this, saying designers are now embracing a “life-cycle approach” when selecting materials for use in new and renovated interior spaces. “In ACJ design studio, we are taking care of the long-term impact of materials. Using sustainable materials will lower the environmental impact caused by various materials and substances,” says Mariat.
It is important to consider both direct and indirect impacts throughout all phases of production process. That includes the use and future removal and disposal of construction materials and supplies.
While awareness of the need to use sustainable materials is becoming more common, the materials themselves are harder to come by, says Eric Gillespie, executive vice president, Flying Colours Corp. “We are beginning to have conversations around sustainability. However, there are still a limited number of sustainable products on the market available and our main guidance is to work with products that meet the required aviation standards.”
Mélanie Prince, head of innovation, of luxury interior manufacturer F/LIST, agrees with Gillespie. “Customers are still very hesitant to compromise on weight, cost, and performance for eco friendliness,” says Prince. This is why the company has come up with its own product portfolio to show sustainable options can “perform adequately and even look better than their conventional counterparts”.
Through a joint venture called Hilitech, which applies lightweight carbon monocoque technology similar to Formula 1 racing, Prince says F/LIST has seen 30% reductions in weight. The company has also used agricultural residuals and industrial leftovers to create decorative materials based on materials from fruit fibre and by-products of its stone-machining department.
Price says F/LIST’s Syntec flooring system is the only vinyl tile flooring concept in the industry. “It eliminates the problems associated with vinyl rolls enabling OEMs, owners and designers to create unlimited, bespoke floor design concepts. That enables the use of individual rectangular or square tiles, or a combination of both.”
Comlux’s Dryer is an advocate for sustainability options in the newly released ACJ TwoTwenty. He says you can have reconstituted veneers, “so you don't have to take new trees down, it can be reclaimed, reconstituted”. Also available is natural fibre carpeting that includes processes that have lower waste, less chemical and faster processing times, according to Dryer. The first ACJ TwoTwenty will be delivered to Comlux.
Some completions teams have a hybrid approach. Take Lufthansa Technik’s ‘Nature’s Touch’ design – a combination of Eastern and Western cultural elements – for a narrow-body aircraft, for example.
Wieland Timm, vice president, Sales VIP & Special Mission Aircraft, Lufthansa Technik, tells CJI: “Nature’s Touch created a symbiosis of nature, technology and human demands. Textile, subtle stripes simulating bamboo wood grain are complemented by natural materials such as marble, genuine leather, wool and silk.”
Nature’s Touch is one of 150 completions done by Lufthansa Technik. These have been aircraft in the Airbus A320-A350 family and Boeing 737-747 range.
Airbus’s Mariat says the details in cabin interiors are extremely vital. “The sweeping strokes of an interior design concept are nothing without the supporting details. A good designer must be detail-oriented,” he says.
Airbus teamed up with French graffiti artist Cyril Kongo, also known as Mr Colourful, to turn each cabin into “a flying contemporary art gallery”, with original designs for each client. The main lounge will be partly hand-painted by Kongo.
Mariat says to further aid the feeling of the home in the sky, he tries to incorporate the client’s everyday belongings into the design. And finally, it is necessary to evaluate an area’s overall composition for balance.
“We can do it by finding a balance starting with the room’s architectural features, like window panels and doors, and then adding in pieces until equilibrium is found,” adds Mariat.
So, there really is next to nothing one cannot do when it comes to cabin interiors. Camber’s Chatfield summed it up perfectly: “There are limits on what can be done to a private jet cabin, but many features can be certified if the client retains a good designer, completion manager and completion centre. Why settle for a ’stock’ cabin when tailored is possible?”
