Time for a Makeover: Inside the Business of Interior Refurbishments

April 16, 2021
When it comes to air travel, nothing feels more luxurious than stepping aboard a modern business jet, as the interiors of these elite aircraft are filled with high-end finishes and amenities. Read on to discover what’s trending now.

Americans love their business jets. In fact, research shows that the United States has by far the largest market in the world, with almost 21,900 business aircraft in operation as of 2019. Yet, about a third of U.S. business jets are more than 10 years old, according to Modor Intelligence, a paradigm that is driving jet operators and charter providers to modernize their planes. And that includes the interiors.

So, what kinds of refurbishments are jet and fleet owners seeking when they upgrade, and how is the market evolving in 2021 and beyond?

Personalized, On Trend and Like Home

Gordon Ross, director of interiors for Pentastar Aviation, noted that most interior upgrades are completed when an aircraft comes under new ownership. “We have projects going right now for newly-acquired airplanes and these customers want to enhance the aircraft to suit their own personal needs and tastes,” he said.

According to Meghan Welch, director of paint and interior sales for Elliott Aviation, jet owners typically seek an upgrade every six to eight years.  “There is wear and tear over time and customers are also looking to keep up with current design trends,” she said.

And what’s trending now is the color gray. “For a partial refurbishment, where an aircraft starts off beige with gold plating, we choose to incorporate warm grays,” said Samantha Boyce, paint and interior design sales associate for West Star Aviation. “For the full refurbishment, we see more cool grays with complementing high contrast materials such as white leather and ebony veneer.” 

Lauren Brocklehurst, senior design manager for Constant Aviation, added that neutrals are always fashionable in the business aircraft market. “Seat design right now favors a modern, slick, taut-leather look,” she said. “We also see people looking for two-toned leather seats and contrast piping or stitching to add visual interest and distinctiveness.”

Jay Rizzo, vice president of sales for Constant Aviation, emphasized the importance of making new interiors feel like home. “Many owners and operators simply want their aircraft to offer the same aesthetics, comforts and lifestyle amenities as their homes,” he said. “When people actually enjoy the experience and sensations of flying, they will return to it again and again.”

For VistaJet, a global private aviation company, that means providing a flight experience for customers that is familiar every time. “The layout of every plane we operate is exactly the same,” said Nick van der Meer, the company’s chief operations officer. “No matter where in the world our customers are, they know exactly what to expect.”

Creating the Perfect Design

Working with customers during the design phase often means giving them an education on the latest trends from factories, OEMs and other jet owners, said Welch.  “We like to make sure customers understand what all their options are. It’s easy to say ‘no’ to something you don’t like.  But we don’t want them to say, ‘I wish I would have.’”

It’s also important to remember that every customer is different.  “We have some customers who really don’t care about the look, and they ask instead for advice on materials that will last longer to get more life out of their investment,” said Ross.  “Other customers are much more into the design aspects.” 

As with any design project, added Boyce, there are key questions to ask, such as whether the aircraft is Part 91 or 135, how many hours it will be operated, whether it will be used for private, personal or corporate trips and who will travel on the aircraft.

“Once we have this information, we are better equipped to guide the customer in the right direction for material selection and placement,” she said, adding that the next steps typically involve an aircraft walkthrough, in-person meeting at the company’s design center or a zoom call.

Brocklehurst emphasizes that it is all about getting to know clients, including their likes, dislikes and preferred styles. “Based on our conversations and any other input the client can provide  pictures, examples from movies and such  our designers come up with options to present,” she said. “From there, we work back and forth with the client to achieve the agreed-upon vision.”

Technical Considerations

According to Ross, one of the biggest priorities of jet owners today is having quality in-flight connectivity. “This is a huge upgrade that everybody is taking advantage of now, especially with Wi-Fi connectivity,” he said. “People love to use their personal electronic devices.”

Van der Meer agrees. “We have put in amazingly high-speed Internet systems for Wi-Fi  brand new technology  and that has been very important,” he said. 

According to Welch, new, high-end lighting systems are increasingly popular with jet owners as well. “We are doing a lot of LED lighting to create a nice ambiance in-flight,” she said.

Designers also have to consider the durability of the materials they select. “The veneers on these jets can crack because of the extreme temperature changes,” said van der Meer. “So, we have pioneered a special material to cover all the bulkheads that replicates wood.”

There are safety considerations as well.  “Everything that goes into an airplane has to be flame tested and treated and certified by the industry,” said Welch. 

A Team Effort

Pulling all the design and functional elements together for customers is a complex challenge. “This is definitely a very skilled trade,” said Welch. “There are a lot of different departments that are involved, from engineering, upholstering and cabinetry to quality control and inspectors. Everything has its own station and it’s all purposed.”

Ross adds that new jet owners often underestimate the time it takes to refurbish an aircraft. “Sometimes we get negotiating with a customer, and they want the aircraft done right away, but custom textiles and carpets have a long lead time,” he said. “So, that is part of our challenge, trying to get the owner to preplan and have a little bit of patience so we can get all the elements ordered and in-house before we start the refurbishments.”

For VistaJet, upgrading the company’s entire fleet in an identical fashion comes with its own set of challenges. “The most complicated part of the process for us is to do the upgrades quickly enough that we can have this new, branded fleet out there that has the exact same offering anywhere in the world,” said van der Meer.  “It’s not that often that someone refurbishes 150 aircraft at once. But we have found the right providers to make sure the downtime, price and scale of these projects are handled well.”

On the Horizon

With technology advancing, design trends changing and consumer travel preferences shifting in a post-pandemic world, what does the future hold?

“Multipurpose aircraft interiors will be the next big thing,” said Brocklehurst. “Most private aircraft are single-purpose-driven. They allow a company to have its senior executives work efficiently while traveling to a big meeting. Or, they enable a family to travel together comfortably on vacation. The pandemic is changing all of that.”

“Now they need to be able to accommodate families, yet be flexible enough to use for business meetings and adaptable for a formal dinner,” she added. “Especially with smaller aircraft, you need to be creative so you can meet all of those needs.”