AkzoNobel’s Aerospace Coatings business and TAP Air Portugal have completed operational trials of a lightweight aircraft basecoat technology that could cut coating weight by up to 26 kg per aircraft, potentially delivering significant fuel and emissions savings across the airline’s fleet.
The trials focused on AkzoNobel’s Aerobase UPD formulation, which reduces total basecoat film thickness by 36% compared with the previous two-coat system while maintaining the durability, appearance and finish quality required for commercial aviation.
Based on projected fleet-wide implementation, the technology could generate annual fuel savings of about 428.5 tons, translating into more than half a million euros in annual cost savings and an estimated reduction of around 1,353 tons of CO2eq emissions.
“We continuously evaluate opportunities to improve operational efficiency and reduce environmental impact across our operations,” explains João Carvalho, Structures Engineer at TAP Air Portugal.
“The results achieved through this collaboration with AkzoNobel Aerospace Coatings demonstrate how relatively small weight reductions, when applied consistently across aircraft fleets, could contribute to meaningful long-term fuel and emissions savings, while also supporting operational efficiency.”
Patrick Bourguignon, Director of AkzoNobel’s Automotive and Specialty Coatings business, says the technology can deliver efficiency gains without compromising finish quality.
“By reducing total film build and simplifying the application process, Aerobase UPD helps operators lower aircraft weight, improve paint shop productivity and maintain the high quality finish standards required across commercial aviation fleets.
“This program with TAP Air Portugal clearly demonstrates how incremental innovations in coating technology can deliver measurable operational benefits and emissions savings for airlines.”
Aerobase UPD achieves the required hiding power and finish quality in a single basecoat application cycle, eliminating the need for a second full basecoat layer and the associated flash-off stages. The formulation also provides approximately 40% greater sag resistance than the traditional two-layer system.
The coating is certified to AMS3095 standards for global mixed-fleet MRO operations. It is also compatible with the upgraded Aerobase activator and existing Aerobase hardeners, allowing operators to integrate the technology into existing paint-shop processes with minimal changes.
For airlines, the results highlight how seemingly small reductions in aircraft weight can add up to measurable savings when applied across large fleets—putting lightweight coating technology on the radar as another tool for improving operational efficiency and reducing aviation emissions.
