For many years, just as in the luxury automotive sector, wood veneer has been the material of choice to add elegance and a quality feel to private, corporate and VIP aircraft. A quality wood veneer, such as Brazilian Rosewood offers an exquisite pallette of warm colours which can create a striking aircraft interior. These rich tones, when combined with leather seating, have enabled Starling to deliver numerous elite cabin environments for corporate and VVIP aircraft. Aside from its aesthetic qualities, wood veneer is used in thin sheets to save weight.

However, when it comes to durability and meeting the necessary fire, smoke, heat release and toxicity regulations, the use of this material is now highly restricted and, in some cases, requires certification exemptions from airworthiness regulations.  Wood veneer can now only be used under special conditions and approval from EASA on new generation aircraft and in older aircrafts that are not required to meet the new cabin safety regulations. Quite often, these older aircraft interiors are refurbished because wood veneer is thin and prone to water and sun damage.  Also, because wood veneer is overlaid onto another substrate which expands and contracts at a different rate, veneers can crack or peel.

Therefore, a wood veneer which was chosen because of its timeless aesthetic quality will typically need replacing. Replacing wood veneer is achievable but can become expensive and lead times are long. This makes a project difficult to manage if the aircraft is only available for a short period, whilst maintenance is carried out. There is also the issue of sourcing a replacement wood veneer which matches in enough quantity, as each cut is unique in its colour and grain. However, one of biggest issues to overcome is the fact that wood veneer doesn’t meet the new stringent fire, smoke, heat release and toxicity regulations.

Therefore, many operators are now using a flame retardant process as an alternative solution. Aqua Transfer which is also known as hydro graphics, dip film or aqua print, is a very unique process which creates a highly decorative finish using vinyl film floated on water. The film can be applied to a variety of substrates used within an aircraft cabin and meets stringent flame and smoke retardant standards.  It is then topped with a lacquer to a matt or high gloss finish. The process is much more time-efficient and is cheaper than using organic materials . When using the Aqua Transfer process, the previous wood veneer thickness is measured and replaced with identical thickness sheet metal or composite material and then routed to shape on Starling’s in-house CNC routers to conform to the identical shape of the original veneer.  The new hydrographic film is applied and top coated with our tested and proven lacquer system, which conforms to the latest flammability regulations.

The end product is a nearly identical match to the original veneer at a fraction of the cost. This durable covering offers great design flexibility as it is possible to create bespoke film. The possibilities are endless when it comes to colour and pattern, which means any wood effect can be easily achieved. The other big advantage is that aircraft interior panels can be easily covered regardless of their size or shape, especially when you have a super-sized tank like the one at Starling Aerospace. Aqua transfer is a quick and a cost-effective way of reviving or transforming an aircraft cabin in good time because of the consistent manufacturing process and availability of aqua transfer films. Although there will always be a place for traditional materials like wood veneer you cannot ignore the huge advantages of covering substrates with aqua transfer.  New film technology provides the depth and appearance of real wood veneer but with the added key benefit of full compliance to the strict flammability requirements for new generation aircraft.  In addition, once in service, should a panel be damaged, it can be repaired to exactly match the existing pattern which is nearly impossible with real wood veneer. It is undoubtedly the best option available to future proof and a create a unique aircraft interior.