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Ascent Aviation and Israel Aerospace Industries Begin Next Phase of Boeing 777-300ER Conversion in Arizona

Ascent Aviation and Israel Aerospace Industries Advance Boeing 777-300ER Freighter Conversion in Arizona
Expansion of Conversion Facilities in Marana
Ascent Aviation Services and Israel Aerospace Industries (IAI) have reached a pivotal milestone in their collaboration to expand the Boeing 777-300ERSF passenger-to-freighter conversion program in North America. The completion of two new widebody hangars at Ascent’s Pinal Air Park facility in Marana, Arizona, marks a significant investment of $70 million and triples the site’s widebody hangar capacity. These 90,000-square-foot facilities are purpose-built to support IAI’s global 777-300ERSF conversion program, positioning Arizona as a strategic hub for next-generation freighter conversions. Preparations are now underway to begin inducting Boeing 777-300ER aircraft for cargo conversion starting in the third quarter of 2026.
Under a long-term agreement, Ascent will operate two Boeing 777-300ERSF conversion lines as IAI’s North American site. The converted aircraft are expected to address the growing global demand for long-haul cargo capacity by extending the operational life of 777-300ER passenger jets through IAI’s advanced freighter modification technology. David Querio, CEO of Ascent Aviation Services, described the new hangars as a “transformational moment” for both the company and the aviation industry in Arizona, emphasizing the partnership’s commitment to innovation, operational excellence, and sustained investment in the future of global air cargo.
Program Developments and Industry Challenges
IAI’s 777-300ERSF program is the first of its kind and has rapidly become a preferred solution for cargo operators seeking increased volume and efficiency. The Marana facility is expected to play a critical role in meeting the anticipated worldwide demand for widebody freighter aircraft. However, the program faces regulatory challenges, particularly with the Extended-range Twin-engine Operational Performance Standards (ETOPS) certification process, which is projected to extend into 2027. This may affect the timeline for full operational deployment of the converted aircraft.
In parallel, IAI is advancing its A330-300 freighter conversion program, which is on track to achieve certification by the end of 2026. These initiatives come amid intensifying competition in the air cargo market, where IAI aims to consolidate its position as a leading provider of freighter conversion solutions. Yaacov Berkovitz, Executive Vice President and General Manager of IAI Aviation Group, highlighted the significance of the Marana hangars and the forthcoming induction of the first aircraft, underscoring the joint effort to establish a world-class conversion operation that supports the growth of the international cargo market.
The expansion is also expected to generate hundreds of highly skilled aviation jobs in Southern Arizona, further cementing Marana’s reputation as a burgeoning aerospace and aviation center. The first Boeing 777-300ER aircraft is scheduled to arrive at the Marana facility in the third quarter of 2026 for conversion under IAI’s Supplemental Type Certificate (STC) program, as both companies continue to navigate regulatory and market dynamics to deliver next-generation cargo solutions.

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