Airbus passenger-to-freighter conversions, lightweight construction from fibre composites, and MRO for civil and military aviation.
Elbe Flugzeugwerke GmbH
Dresden · KodersdorfNew on Amplifa
About Elbe Flugzeugwerke
Elbe Flugzeugwerke GmbH (EFW), based in Dresden, is an aviation company with three core business areas: certified passenger-to-freighter (P2F) conversions of the entire Airbus family (A330, A321, A320), the development and production of lightweight composite components, and maintenance, repair and overhaul (MRO) for civil and military aircraft including the A380 and the NH90 helicopter. In lightweight construction, EFW manufactures sandwich panels, laminated panels and VAP® components made of glass and carbon fibre with honeycomb or foam core on automated production lines and has been an exclusive Airbus supplier for over 30 years. As an EASA-approved 21J design organisation (EASA.21J.054), EFW develops its own Supplemental Type Certificates and supports the freighter programmes throughout their entire life cycle. The company is a joint venture of ST Engineering (55%) and Airbus (45%), employs over 2,000 people and generated revenue of over €600 million in 2023. In addition to its Dresden headquarters, the subsidiary acosa GmbH manufactures lightweight components in Kodersdorf; global partner networks supplement the P2F capacities.
- Site
- Dresden
- Processes
- Passenger-to-freighter conversion (P2F) A330, Passenger-to-freighter conversion (P2F) A321, Passenger-to-freighter conversion (P2F) A320, A310 conversion to freighter/MRTT (historic), MRO / Line & Base Maintenance Airbus A300, A300-600, A310, A319, A320, A321, A330, A340, A380 (via, NH90 helicopter maintenance (TGEE, TGEA), Component maintenance per Component Capability List (except complete engines/APUs), Non-destructive testing (dye penetrant testing, ultrasonic testing, eddy current testing,
- Materials
- Glass fibre (GFRP), Carbon fibre (CFRP), Prepreg (pre-impregnated fibres), Honeycomb core, Foam core, Epoxy resin, Polyester resin, Metal parts (inserts in sandwich panels)
- Certificates
- EN 9100:2018, EN 9110:2018, DIN EN ISO 14001:2015, DIN EN ISO 50001:2018, EASA Part-21J Design Organisation, CASA Approved Design Organisation, EASA Part-145 Maintenance, Part-21G Production, Part-CAMO, CASR Part 145 Maintenance, DEMAR 145 Maintenance, ECAR Part 145, CCAR 145, SHT-145, Part-145 (UK), OTAR Part 145, Part-145 (TCCA), FAA Part-145, DIN 2303, ISO 14001:2015, ISO 50001:2018, EASA Part-21J Design, EASA Part-145, DIN 2303 (Welding Q4/BK3)
- Founded
- 1955
- Employees
- 2,000+
- Industries
- Aerospace, Civil aviation, Military aviation, Rail transport, Rail transport (lightweight construction)
- 01
Engineering and design (EASA 21J)
- 02
CNC cutting of prepregs and tape laying
- 03
VAP® resin infusion or sandwich manufacturing
- 04
Press and oven curing
- 05
3-/5-axis CNC machining and deburring
- 06
Painting and decoration
- 07
Assembly and kitting
- 08
In-house material testing
- 09
P2F conversion and MRO
- 10
CAMO and customer support
Materials and Processes
Glass fibre (GFRP)
Laminated and sandwich panels for aircraft floors and cabin interiors.
Carbon fibre (CFRP)
High-strength lightweight structures and weight-reduced cabin components.
Prepreg (pre-impregnated fibres)
CNC-cut, pre-impregnated fibres for automated and manual tape laying.
Honeycomb core
Core material for sandwich panels, CNC-machined and potting-filled.
Foam core
Alternative core materials for sandwich constructions.
Epoxy resin
Matrix resin for laminated and VAP® structural components.
Polyester resin
Resin system for laminating in fibre composite production.
Metal inserts
Metal parts for load introduction, installed before the panels are cured.
Sites
Dresden
DEHeadquarters; central site for Airbus P2F conversion, MRO and lightweight construction manufacturing
- Materials
- GFRP, CFRP, honeycomb and foam core, epoxy/polyester resin
- VAP® production line
- Automated sandwich production lines
- 2 assembly lines
- 3-axis CNC machining machine
- 5-axis CNC machining machine
- Press curing system
- Oven curing system
- Hangar 230 (A330P2F, A380 MRO)
Kodersdorf
DELightweight construction manufacturing (acosa GmbH / CCI-Assembly)
- Materials
- GFRP, CFRP, fibre composites
Components and Products
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Passenger-to-freighter conversion (P2F) A330Assembly | – | – | – | – | Aluminium, Aluminium alloys (structural components, inferred) |
| Passenger-to-freighter conversion (P2F) A321Assembly | – | – | – | – | – |
| Passenger-to-freighter conversion (P2F) A320Assembly | – | – | – | – | – |
| A310 conversion to freighter/MRTT (historic)Assembly | – | – | – | – | – |
| MRO / Line & Base Maintenance Airbus A300, A300-600, A310, A319, A320, A321, A330, A340, A380 (viaAssembly | – | – | 5700 kg | – | – |
| NH90 helicopter maintenance (TGEE, TGEA)Assembly | – | – | – | – | – |
| Component maintenance per Component Capability List (except complete engines/APUs)Assembly | – | – | – | – | – |
| Non-destructive testing (dye penetrant testing, ultrasonic testing, eddy current testing,Testing | – | – | – | – | – |
| Welding (Type 4 – tungsten inert gas welding / gas tungsten arc welding; DIN 2303 class Q4, BK3,Joining | – | – | – | – | – |
| Manufacture of sandwich panels (glass fibre/carbon fibre with honeycomb or foam core)Plastics | – | – | – | – | Glass fibre (GFRP), Carbon fibre (CFRP), Honeycomb core, Foam core |
| Laminated panel manufacturing (GFRP/CFRP, optionally with core material)Plastics | – | – | – | – | Glass fibre (GFRP), Carbon fibre (CFRP) |
| VAP® components (vacuum resin infusion, monolithic or sandwich)Plastics | – | – | – | – | Glass fibre (GFRP), Carbon fibre (CFRP) |
| CNC cutting of prepregs, automated and manual tape layingPlastics | – | – | – | – | Prepreg (glass fibre/carbon fibre) |
| Machining of honeycomb material (CNC potting of cells, core filling)Plastics | – | – | – | – | Honeycomb core |
| Press curing and oven curing (curing of composite components)Plastics | – | – | – | – | Fibre composites, Epoxy resin, Polyester resin |
| 3- and 5-axis CNC machining, automated deburringMachining | – | – | – | – | Fibre composites, Honeycomb core |
| Painting (including environmentally friendly water-based paints) and decorative film applicationSurface | – | – | – | – | – |
| Complex assembly/kitting work on composite components (two assembly lines)Assembly | – | – | – | – | Fibre composites |
| Design and manufacture of production toolingEngineering | – | – | – | – | – |
| Mechanical testing: tensile, compression and shear tests for sandwich components, core materials andTesting | – | – | – | – | Sandwich components, Core materials, Laminated panels |
| Engineering services (EASA 21J design organisation, STC development, concept design throughEngineering | – | – | – | – | – |
| CAMO services (continuing airworthiness management, A330, A318, A319, A320, A321)Engineering | – | – | – | – | – |
| Borescope inspection / Specialized Services (Mexican approval)Testing | – | – | – | – | – |
8 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| VAP® production line (layup, cutting, preforming, resin infusion, curing) | – | – | – | – | Dresden / Kodersdorf |
| Automated sandwich production lines | – | – | – | – | Dresden / Kodersdorf |
| Assembly lines | – | 2 | – | – | Dresden / Kodersdorf |
| 3-axis CNC machining machine | – | – | – | – | – |
| 5-axis CNC machining machine | – | – | – | – | – |
| Press curing system (press curing) | – | – | – | – | – |
| Oven curing system (furnace curing) | – | – | – | – | – |
| Hangar 230 (A330 conversion and A380 MRO) | – | – | – | 2017 | Dresden |
Additional services
Reference customers
Quality and Approvals
EFW holds a comprehensive portfolio of approvals from international aviation authorities (EASA, FAA, CASA, CAAC, among others) as well as certifications under EN 9100, EN 9110, ISO 14001 and ISO 50001. Its in-house testing laboratory performs non-destructive testing methods (dye penetrant, ultrasonic, eddy current, thermography and radiographic testing) as well as mechanical tests (tension, compression, shear, bending).
| Evidence | Dresden | Kodersdorf |
|---|---|---|
| EN 9100:2018 | ||
| EN 9110:2018 | ||
| ISO 14001:2015 | ||
| ISO 50001:2018 | ||
| EASA Part-21J Design | ||
| EASA Part-145 | ||
| Part-21G Production | ||
| DIN 2303 (Welding Q4/BK3) |
History
- 1955
Founded as VEB Flugzeugwerke Dresden; start of aircraft development and production (Baade 152, licensed production of the Ilyushin Il-14P)
- 1961
Discontinuation of aircraft manufacturing in the GDR; transition to maintenance of civil and military aircraft (VEB Flugzeugwerft Dresden)
- 1990
Foundation of Elbe Flugzeugwerke GmbH by DASA and Airbus (27 April 1990)
- 1991
Elbe Flugzeugwerke GmbH established as an Airbus subsidiary
- 1993
Airbus relocates production of composite components to Dresden; start of lightweight construction production
- 1996
First passenger-to-freighter conversion of an A310
- 1998
A310 conversion to Multi-Role Tanker Transport for the German and Canadian air forces
- 2000
Launch of independent MRO business for passenger aircraft
- 2002
Certification as a 21J design organisation; first own STC
- 2005
Expansion of lightweight construction manufacturing and infrastructure
- 2013
Foundation of CCI-Assembly as a subsidiary for composite production in Kodersdorf
- 2014
First A380 MRO project (customer: Airbus)
- 2015
ST Engineering becomes principal shareholder alongside Airbus
- 2017
New Hangar 230 for A330P2F and A380 MRO
- 2018
Foundation of acosa GmbH as a second production site for lightweight components
- 2019
Start of helicopter MRO (NH90) for the German Armed Forces (Bundeswehr)
- 2017-2022
Launch of the new conversion programmes A330P2F, A321P2F and A320P2F; conversion sites on three continents
- 2022
Jordi Boto (CEO) and Kai Mielenz (CFO) have formed the executive board since September 2022