With delays in new aircraft manufacturing and the growing number of aging aircraft in service, the need for efficient heavy maintenance solutions is more critical than ever. The new FL Technics MRO facility in Punta Cana is being developed to meet this demand, with large composite and heavy sheet metal structure repair workshops equipped with specialized machinery and an extensive repair scope.
As demand exceeds manufacturers’ ability to supply new aircraft, the airlines continue operating their current fleets well into their service. To sustain the aging aircraft safely and reliably until eventually replaced by next-generation ones, aircraft maintenance, repair, and overhaul (MRO) service providers are looking for efficient ways to handle the growing demand.
A new heavy maintenance hangar by FL Technics, a global MRO services provider, now under construction in Punta Cana, Dominican Republic, is one example of how the industry is responding. Namely, by choosing strategic locations close to major aviation hubs and focusing on the maintenance of specific aircraft models. This approach allows for optimized turnaround times (TAT) without compromising service quality.
As aircraft age, their structures and materials require more specialized attention. Today’s fleets combine reinforced composites with conventional metals, making maintenance not only more complex but also time-sensitive.
According to Juozas Lapeika, Deputy CEO for Base Maintenance at FL Technics, turnaround efficiency is the top priority for most low-cost carriers operating aging narrow-body fleets. To meet this demand, the upcoming FL Technics’ heavy maintenance facility in Punta Cana will be dedicated specifically to heavy airframe checks for a targeted scope of Airbus A320 and Boeing 737 family aircraft. This focus enables the deployment of large, dedicated teams working in parallel to perform the operations rapidly and ensure faster aircraft redelivery.
“The strategic move to open a new heavy maintenance center in Punta Cana — a location previously without independent MRO services — is based on our proven global experience,” says Mr Lapeika. “Heavy defects are our niche, and we will aim to become the top-choice MRO provider in the region. Our goal is to deliver not only top quality service but also the best turnaround times, something we can achieve by focusing on a defined scope of aircraft, allowing us to use our expertise and master every detail. Servicing a broad spectrum of aircraft would not allow the same depth and precision.”
The new hub will be developed in three phases, starting with five bays initially and expanding to twenty in subsequent years. To perform heavy checks quickly and efficiently, FL Technics will equip the new facility with advanced infrastructure and specialized workshops for heavy sheet metal structures, composites, paint, and advanced NDT (non-destructive testing).
Essential to success in today’s MRO sector is also the development of specialized knowledge among technicians and engineers. To this end, FL Technics Dominican Republic is partnering with local vocational institutions and will introduce train-to-hire programs to prepare new specialists for work on both older and next-generation fleets.
“To perform maintenance services quickly and efficiently, we need a dedicated team with strong expertise. We are relocating experienced aviation professionals from our facilities worldwide to guide and mentor Dominicans who want to start careers in aviation maintenance,” says Mr Lapeika. “Our workforce will have access to the best tools and know-how, so customers won’t need to look abroad for these skills.”
The opening of the new FL Technics hangar is scheduled for the end of this year, with recruitment already underway. The company plans to hire 300 employees during the first phase and expand the team up to 2,000 in the coming years.
