AkzoNobel Aerospace Coatings has unveiled a new single-coat version of its Aerobase basecoat system, designed to significantly improve performance, efficiency and throughput in aircraft paint facilities. By replacing the traditional two-coat application process with a validated single-coat solution, the enhanced Aerobase formulation reduces application time, process complexity and total film thickness, while delivering a consistent, high-quality finish across mixed aircraft fleets.
Developed specifically for the global MRO mixed fleet market, the new solution is certified for immediate worldwide use, enabling paint facilities to adopt the single-coat process without delay.
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As part of AkzoNobel Aerospace’s continuous improvement programme, the development of the enhanced Aerobase system focused on optimising application control, film build consistency and finish quality in performance-critical MRO environments.
The new formulation delivers approximately a 40% improvement in sag resistance compared to the original system. When combined with a cross-coat application technique, this enables full hiding power and surface finish to be achieved in a single basecoat layer, effectively replacing the traditional two-coat approach.
Field testing conducted in 2025 on a single-aisle aircraft demonstrated a 36% reduction in total film thickness compared with a conventional two-coat system. Importantly, this reduction was achieved without compromising durability, appearance or surface quality.
In addition to improving finish consistency and surface smoothness, the thinner coating contributes to lower aircraft operating weight, which can translate into reduced fuel burn and lower associated CO₂ emissions for airlines, supporting both operational efficiency and sustainability objectives.
Commenting on the development, Aurore Bournazel, Segment Manager, OEM, MRO & Airlines, said the focus was on solving real-world challenges faced by paint facilities: “MROs are under constant pressure to improve efficiency without compromising quality. This latest Aerobase development enables a validated single-coat process that simplifies application, improves consistency and delivers measurable performance benefits. By reducing total film thickness, it also supports airlines’ efforts to lower aircraft weight, helping to reduce operating costs and associated CO₂ emissions. It’s a practical solution designed to help paint facilities do more with less today.”
The enhanced Aerobase single-coat solution will initially be available in the most commonly used aerospace white colours, ensuring immediate relevance for airlines and MRO operators worldwide.
AkzoNobel Aerospace Coatings’ technical teams are actively supporting MROs with process development, validation and applicator training, ensuring consistent and repeatable results across facilities.
The product is already certified for global use within the MRO mixed fleet market, allowing immediate deployment in operational paint facilities. OEM testing and approval processes are underway and expected to follow.
Additional aircraft applications are currently in progress with two MROs, covering both single-aisle and widebody aircraft. These programmes, together with last year’s testing, will provide robust, real-world performance data to help airlines and MROs make informed decisions on efficiency, weight reduction and finish quality.
AkzoNobel Aerospace Coatings plans a phased global rollout of the enhanced Aerobase single-coat system throughout 2026, reinforcing its commitment to innovation, operational efficiency and sustainability across the aerospace coatings sector.
