First Boeing 777-300ER Enters IAI9s Freighter Conversion
Programme in North America
AeroMorning 9 John Smith 9 October 22, 2026
Israel Aerospace Industries (IAI), Ascent Aviation Services
and World Star Aviation have announced the start of Boeing 777-300ERSF
passenger-to-freighter (P2F) conversions in North America. The announcement,
issued on October 22, 2026, confirms that the first Boeing 777-300ER passenger
aircraft from World Star Aviation9s portfolio has arrived at Ascent Aviation
Services9 newly expanded facility at Pinal Air Park in Marana, Arizona, to
undergo conversion into a dedicated freighter.
The project marks an important milestone in the
international expansion of IAI9s Boeing 777-300ERSF programme. By establishing
a North American conversion location, IAI and its partners aim to increase
production capacity, bring specialised modification services closer to regional
customers, and respond to growing demand for long-haul air cargo capacity.
Official press release: c2ab IAI, Ascent Aviation
Services and World Star Aviation Announce Commencement of Boeing 777-300ERSF
Passenger-to-Freighter Conversions in North America, c2bb
A New North American Conversion Centre in Arizona
Under a long-term agreement with IAI, Ascent Aviation
Services will operate two parallel Boeing 777-300ERSF conversion lines at its
Marana facility. The site will become part of IAI9s global
passenger-to-freighter conversion network, expanding the company9s ability to
serve cargo operators in North America.
The launch follows the completion of two new widebody
aircraft hangars, each measuring 90,000 square feet, or approximately 8,360
square metres. The project represents a $70 million investment and triples the
hangar capacity at Ascent9s Marana facility, substantially expanding its
heavy-maintenance and widebody modification capabilities.
The expansion is expected to create hundreds of highly
skilled aviation jobs in Southern Arizona, strengthening Marana9s position as a
growing aerospace and aviation centre. The new infrastructure combines IAI9s
certified conversion technology with Ascent9s maintenance, repair and overhaul
(MRO) capabilities and experience in supporting large commercial aircraft.
IAI holds the Supplemental Type Certificate (STC) for the
Boeing 777-300ERSF conversion programme, having obtained certification in
September 2025.
The Boeing 777-300ERSF: A Large-Capacity Long-Haul
Freighter
The Boeing 777-300ERSF, marketed by IAI as the ab Big Twin bb,
is a passenger-to-freighter conversion of the Boeing 777-300ER. Rather than
building an entirely new cargo aircraft, the programme modifies existing
passenger aircraft to extend their operational lives and adapt them to the
requirements of the air freight market.
The modified aircraft is intended to offer cargo operators
substantial payload capacity, long-range operating potential and the ability to
accommodate a broad range of standardised cargo containers and pallets.
According to IAI9s published technical brochure, the
converted aircraft has the following indicative specifications, subject to the
basic aircraft configuration:
Specification | IAI-published figure |
Maximum take-off weight (MTOW) | 775,000 lb (approximately 351.5 tonnes) |
Maximum payload | 222,000 lb (approximately 100.7 tonnes) |
Main-deck cargo volume | 28,936 ftb3 (approximately 819 mb3) |
Lower-deck bulk cargo volume | 600 ftb3 (approximately 17 mb3) |
Fuel capacity | 47,890 US gallons (approximately 181,300 litres) |
Main-deck loading configuration Lower deck loading configuration | Up to 33 ULD positions in the specified configuration Up to 14 ULD positions |
The main deck can accommodate different unit load device
(ULD) configurations, including standard cargo containers and larger pallet
formats. This flexibility allows operators to tailor loading arrangements to
different freight types and operational requirements.
The aircraft9s high payload capacity and substantial cargo
volume make it suitable for long-haul freight operations, including express
logistics, e-commerce shipments, general cargo and other high-volume transport
requirements. Its conversion also provides a way to bring existing passenger
aircraft into the cargo market as operators seek to expand capacity and manage
fleet investment costs.
About IAI
IAI is a leader in passenger-to-freighter
aircraft conversions. The company9s wider portfolio includes
passenger-to-cargo conversions, Maintenance, Repair, and Overhaul (MRO)
services, business jet customization, aerostructures, aircraft upgrades,
and more. In its 2025 financial results, IAI reported total revenue of
approximately $7.384 billion. Its Aviation Group generated approximately $1.608
billion in sales during the year, up from approximately $1.476 billion in 2024.
About Ascent Aviation Services
Ascent Aviation Services is one of the largest independent
aircraft aftermarket service providers in the world, offering heavy
maintenance, component MRO, flight line, storage, and reclamation services to
owners, operators, and lessors of wide-body, narrow-body, and regional
aircraft. Ascent is a Class IV FAA 14 CFR Part 145 certified repair station and
has maintained a strong and continuous workforce in Arizona for more than 40
years.
About World Star Aviation
World Star Aviation is a leading full-service aircraft and
engine lessor with a superior track record in mid-to-late life assets. World
Star enhances value for both investors and airlines alike through its rigorous
and globally recognized asset management style. Over the past number of years,
World Star has built a strong global presence in the cargo market with 60
narrow and widebody freighters on lease to cargo operators around the world.
The company boasts a strong track record with a portfolio of approximately 150
aircraft and engines.
Market Outlook: Meeting Demand for Long-Haul Cargo
Capacity
Passenger-to-freighter conversions have become an important
option for cargo operators seeking additional capacity without relying
exclusively on newly built freighters. Converting existing aircraft can extend
the useful life of airframes, create additional cargo capacity and offer
operators another way to manage fleet investment.
The Boeing 777-300ERSF is designed to serve the widebody
cargo segment, where payload capacity, cargo volume and long-haul capability
are important considerations. Its entry into the North American conversion
market is intended to provide operators in the region with greater access to
specialised conversion services.
Conclusion
The arrival of World Star Aviation9s first Boeing 777-300ER
at Ascent Aviation Services9 Marana facility marks the start of IAI9s Boeing
777-300ERSF passenger-to-freighter conversion operations in North America.
The project also illustrates how aircraft manufacturers,
conversion specialists and leasing companies can work together to expand cargo
capacity by adapting existing passenger aircraft.
