Why cold spray is positioned to become the new standard for aircraft wing skin repair

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Calum Hicks, senior technologist at the Digital Factory, National Manufacturing Institute Scotland (NMIS)

Aircraft continually operate in demanding environments that can challenge the integrity of wing skins. Corrosion of these components remains one of the most costly and persistent challenges in aviation manufacturing, creating critical maintenance obstacles for the sector. Corrosion drives extensive downtime, requires repeated interventions, and disrupts efficient workflow planning.

Despite the ability of traditional repair methods - such as epoxy filler and doubler plates - to extend aircraft life through material replacement and reinforcement techniques, they also bring about the need for frequent repairs, limiting operational efficiencies. 

Modern aircraft operate in demanding environments and due to the high safety margins required by the industry, they have a very low tolerance for any component damage or degradation. The industry therefore needs a more resilient, durable approach to wing skin restoration - one that can withstand extreme conditions while reducing repeat maintenance and cost.

Addressing this challenge requires a shift away from traditional repair practices and towards advanced manufacturing techniques that can re-shape resilience. Crucially, any new approach must integrate seamlessly into existing MRO operations without introducing excessive disruption or complexity.

Cold spray manufacturing represents that shift.

This additive manufacturing technology – a solid-state process that forms metal parts by firing metallic powder at supersonic speed - offers a significantly more corrosion-resistant repair and longer lasting alternative to epoxy-based methods. Through dimensional restoration, cold spray rebuilds damaged wing skins to their original specifications, by replacing the damaged material with new aluminium alloy. The result is a longer service life and a reduced need for repeat repairs.

Unlike other additive manufacturing processes, cold spray can be applied directly inside hangars thanks to its low operating temperatures and portable functionality. This provides immediate access to damaged wing skins – transforming the engineering that can be carried out inside the maintenance facility. Used this way cold spray has the potential become the new standard for aircraft wing skin repair. 

The cold spray process can treat corrosion-affected areas within hours, significantly outperforming traditional methods that can take days to complete due to curing requirements, underscoring cold spray’s suitability as a core aircraft repair process. 

Cold spray also supports the aviation industry’s transition towards greater sustainability. By restoring the original material with cold spray technology, it allows for components to remain in service for longer, reducing material waste and supporting the sectors transition to a low-carbon economy.

Yet, despite its clear advantages, widespread UK adoption of cold spray is hindered by barriers that require targeted investment as operators need specialised training, and the process must undergo rigorous validation and certification to meet stringent aerospace standards. 

Safety concerns also persist, as cold spray equipment generates extreme noise and involves the handling of hazardous metallic powders. These challenges are reasons to invest in workforce skills and robust safety measures, and to accelerate the UK’s capability in this fast-growing technology.

Countries such as the USA, Canada and Germany are already considered leaders in the development and application of cold spray technology, with extensive use across various manufacturing sectors. Their success highlights the strategic importance of early investment and the opportunity for the UK to strengthen its position in advanced aircraft manufacturing.

The aviation industry is now entering a new era of maintenance and repair. Traditional techniques, that once served the industry well, are no longer appropriate for the requirements of modern aircraft manufacturing where efficiency, sustainability and engineering excellence are essential. Cold spray additive manufacturing offers a future-proof solution that meets these demands. By embracing the technology now, the sector can move beyond outdated practices and transform industry standards for aircraft resilience.

LEEA introduces Proficiency Testing

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LEEA (Lifting Equipment Engineers Association) is rolling out a new form of assessment called Proficiency Testing. The optional proficiency test, which is conducted in a practical environment, offers a modern, more dynamic form of testing and has been introduced in response to feedback from LEEA members.

This pioneering approach moves from theory-only testing to a real world demonstration of proficiency, with learners applying their knowledge across three key stages:

• Preparation and planning
• Process
• Reporting and justification.

These stages are assessed against equipment in known conditions of repair, with learners demonstrating their true proficiency by passing each stage to achieve the relevant LEEA diploma. The same pass criteria applies across both MCQ and Practical Test routes, ensuring consistency in standards, quality and reliability. Practical Test days are scheduled to give flexibility around when assessment takes place.

Matt Barber, LEEA Director of Membership, commented: “Having listened to our members, we have designed our new Proficiency Testing for those who prefer to demonstrate their skills through hands-on inspection. Not all learners feel at ease with online multiple choice assessments, yet for years this has been the standard – a single format and a single measure, but is that enough in an industry built on real world skill? LEEA’s new Proficiency Testing is a shift in mindset to a learner-centred, inclusive approach to qualification. It challenges industry standards and embraces initiative to create fair and reliable outcomes.”

He added: “Rather than replacing the existing route – the multiple-choice assessment remains available. So this creates choice and provides an inclusive route to qualification by supporting different styles and removing unnecessary barriers.”

For more information and to secure your spot, visit leeaint.com/courses.

Chell Instruments reflects on ‘best year to date’ following major company milestones

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World-leaders in gas measurement and control solutions, Chell Instruments, have celebrated one of their best years in business as the financial year came to a close.

Between April 2025 to April 2026, the business achieved its highest turnover to date while reaching several significant milestones, including five exciting new product launches, continued support for university engineering programmes, 25 years of ISO accreditation and recognition with a regional manufacturing award.

“The past year we have continued innovating in precision measurement technology, supported the next generation of engineers, maintained the highest quality standards and gained recognition for our manufacturing excellence. We’re incredibly proud of what the team has achieved and would like to thank every member of staff, customer and partner who has contributed to our best year to date!” says Jamie Shanahan, Director of Chell Instruments.

Over the past year, Chell Instruments introduced enhancements to their product range, including improved scanner data-transfer efficiency through CAN-FD technology.

The company also expanded its portfolio of industry-leading scanner products, launching the new 2401/2402 reference standard, picoDAQ miniature scanner, 2432T thermocouple scanner and 2416 industrial pressure scanner.

Remaining committed to exceptional standards in testing, calibration and quality management, Chell Instruments were recertified to ISO 9001:2015 and celebrated its 25th consecutive year of ISO 17025 (UKAS) accreditation for their calibration laboratory (laboratory No. 0687).

Chell also donated a nanoDAQ-LTS-16 pressure scanner to a Hungarian University’s Formula Student Electric Team, helping them refine aerodynamics in their Formula-style racing vehicle and gain hands-on experience with advanced pressure measurement technology.

The company’s achievements were further recognised in February this year when Chell Instruments proudly received the Inspiring North Norfolk Award for ‘Excellence in Manufacturing’.

“At Chell, we’re always committed to continually improving what we offer and supporting the industries that rely on precision measurement technologies. The hard work and dedication of our company have truly paid off over these past 12 months - marking a year of innovation, industry recognition and continued investment in future engineering talent” adds Jamie.

Established in 1976, North Walsham-based Chell Instruments produce pressure, vacuum and gas flow measurement and control solutions.

Providing some of the lowest measurement uncertainties on the market, Chell Instruments’ specialist technology is adopted by key sectors, including aerospace, pharmaceuticals, energy and motorsport.

“2025 - 2026 has been our best year - so far! With ambitious plans, exciting product developments and a strong pipeline ahead, we’re looking forward to building on this momentum and making the year ahead even more successful – watch this space!” concludes Jamie.

For more information on Chell Instruments, please visit www.chell.co.uk 

Satron’s Precision Turbidity Measurement is Transforming CIP Washline Efficiency

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In an era of soaring energy costs and stringent environmental regulations, the dairy sector is under pressure to de-carbonise. We explore how moving from time-based flushing to optical phase detection can significantly bolster the bottom line.

In the dairy industry, hygiene is non-negotiable. However, maintaining the highest food safety standards frequently comes at a significant environmental and operational cost. Clean-in-Place (CIP) processes are notoriously resource-intensive, often accounting for a large portion of a site’s water, energy, and chemical consumption.

For Sustainability Managers and Production Directors alike, the challenge is clear: how can you meet ambitious Net Zero targets without compromising product integrity or plant throughput? The answer lies in moving away from conservative estimates and embracing high-precision process transparency.

The Hidden Cost of Traditional CIP

Many legacy CIP systems still rely on simple time-based washing or basic conductivity measurements to trigger phase transitions. By its very nature, this approach is overly cautious. To guarantee that no cleaning chemicals or product residues remain in the pipework, systems are typically programmed to ‘over-flush’.

The result is a costly drain on resources. Every day, thousands of litres of clean water, valuable dairy product, and expensive detergents are sent straight to the effluent plant. This doesn’t just inflate raw material and utility bills; it also significantly increases wastewater treatment charges, a growing concern for UK operators facing tighter discharge consents. To truly optimise the process, plants must transition from guesswork to exact measurement.

Precision via Optical Turbidity

To minimise waste, operators need to know exactly what is flowing through the process line at any given millisecond. This is where the Satron VO turbidity sensor provides a critical competitive advantage.

Utilising advanced optical measurement technology, the Satron VO delivers accurate, real-time data on the liquid’s composition. Rather than relying on a timer to ‘guess’ when a rinse is complete, the sensor identifies the exact cut-points between product, water, and cleaning agents. By measuring turbidity, the sensor detects even the slightest change in concentration, allowing the automation system to switch valves at the precise optimal moment.

Driving ROI and Sustainability

Implementing precise optical measurement transforms CIP from a rigid, wasteful procedure into a highly optimised, data-driven process. These improvements directly impact a plant’s Key Performance Indicators (KPIs):

• Minimised Water Consumption: By halting the rinse cycle the moment the water runs clear, dairies can eliminate unnecessary flushing, saving millions of litres of fresh water annually.

• Reduced Chemical Expenditure: Accurate cut-points ensure that expensive detergents are recovered and reused rather than lost to the drain. This lowers procurement costs and reduces the chemical load on the local water authority’s infrastructure.

• Thermal Energy Savings: Heating water and chemicals for CIP cycles requires massive amounts of energy. By reducing the total volume of fluids used, the energy required for heating drops proportionally—a vital saving given current UK energy prices.

• Maximised Product Yield: Precision phase detection prevents valuable milk or cream from being accidentally flushed away during the initial pre-rinse phase, ensuring more product reaches the bottle or carton.

Maintenance Without Downtime: The PASVE® Advantage

Operational efficiency isn't just about the process; it’s about uptime. The Satron VO sensor can be seamlessly paired with the PASVE® mounting and service valve. This strategic combination allows sensors to be safely isolated, removed, cleaned, or calibrated without the need to stop the process or drain the line.

This ‘hot-swappable’ capability ensures continuous operational availability while significantly improving health and safety for maintenance personnel, as they are not exposed to hot or caustic process fluids during sensor servicing.

Conclusion: Achieve More by Wasting Less

Achieving sustainability in the Food & Beverage sector does not require a trade-off with hygiene or efficiency. By upgrading to Satron VO turbidity sensors, UK dairies can rely on exact calculations to drive immediate ROI, reduce their environmental footprint, and future-proof their production lines against rising costs.

It is time to look closer at your CIP cycles. The opportunity for significant savings is already flowing through your pipes.

If you are not attending the Food & Beverage Engineeering exhibition at Derby Arena on the 16^th June, then call PLUS Automation on 0121 58 222 58 or email This email address is being protected from spambots. You need JavaScript enabled to view it. and we will bring a unit to show you. PLUS Automation helps engineers #MakeSenseofSensors and #MakeSenseofSafety using Inductive, Machine Safety, Photoelectric, Pressure, Process, RFID & Ultrasonic sensors from Contrinex, ReeR Safety & Satron.