873 Airbus A320 Fuselage Panels

Airbus A320 fuselage panel problems, Thunderbird F-16C crash, ATC prime integrator, hand flying, Boeing and Spirit AeroSystems, Southwest Airlines meltdown fine, solar flares and A320 groundings, airline pay-for-delay compensation, and charging air travelers without REAL ID.

Aviation News Airbus prepares A320 inspections as fuselage flaw hits deliveries

Airbus engineers are inspecting 628 A320 family exterior fuselage panels for thickness defects. The skin panels have thickness deviations beyond Airbus’s design tolerances. The panels were manufactured by a Spanish supplier Sofitec Aero and do not represent a flight‑safety risk at this time. Panels on the upper forward fuselage are the main concern, with deviations having also been found in some rear‑fuselage sections. The affected panels are not serialized, so Airbus must inspect the entire batch of potentially impacted airframes rather than trace specific parts.

A320 Family final assembly line in Toulouse. Courtesy Airbus.

Sofitec Aero is an aerostructures company that designs, manufactures, and assembles metallic and composite aircraft structures for major OEMs, including Airbus, Boeing, Embraer, Bombardier, and several Tier‑1 suppliers such as Spirit AeroSystems and Stelia. It is a privately held firm, founded in 1999.

Thunderbirds F-16C Fighting Falcon Crashes in California

The 57th Wing Public Affairs Office issued a statement saying, “On December 3, 2025, at approximately 10:45 a.m., a Thunderbird pilot safely ejected from a F-16C Fighting Falcon aircraft during a training mission over controlled airspace in California. The pilot is in stable condition and receiving follow-on care.”

The F‑16C went down during a routine training mission in controlled airspace over the Mojave Desert. The crash site is located in a remote desert area near the town of Trona, approximately two miles south of Trona Airport and about 27 miles from Naval Air Weapons Station China Lake.

Hydrazine: A Significant Hazard Each Time An F-16 Crashes (Or Fires Up The Emergency Power Unit)

F‑16s use hydrazine in their emergency power units, so environmental and hazmat teams from Edwards Air Force Base were deployed to the site to evaluate and mitigate any hazardous materials concerns.

The F-16’s Emergency Power Unit (EPU) is a backup power system that utilizes H-70 (approximately 70% hydrazine and 30% water) to drive a small turbine, supplying emergency hydraulic and electrical power in the event of main engine or generator failure.

Hydrazine is used because it is a monopropellant that can rapidly generate mechanical power without external oxygen, but it is also highly toxic, corrosive, and flammable, so its use is tightly controlled and largely limited to legacy or niche applications.

US government selects contractor Peraton to lead air traffic control modernisation

In Episode 865, we reported that two bids had been received to become the prime integrator for the FAA’s project to overhaul the air traffic control system, called the Brand New Air Traffic Control System (BNATCS). They were Peraton and Parsons Corporation. Congress had approved $12.5 billion for the project, and the Agency has indicated that an additional $19 billion might be requested.

The US Department of Transportation (DOT) selected Peraton as the prime integrator. The national security company is owned by Veritas Capital and headquartered in Reston, Virginia. Flight Global says Peraton is a “provider of technologies for large, complex organisations, offering services including cyber security, systems engineering and modernisation, cloud computing and data management.”

According to Veritas, the company specializes in buying and growing companies that sell technology and services to U.S. government agencies in defense, intelligence, civil, and health markets. Examples include acquisitions or control of federal IT and mission‑support businesses such as Northrop Grumman’s federal IT arm (combined into Peraton) and health IT and analytics providers serving Medicaid and Defense Health Agency programs.

See also, What to know about the air traffic control overhaul and the company FAA hired to manage it.

Union Urges ‘Back-to-Basics’ Approach to Pilot Skills

Captain Wendy Morse is a Boeing 787 captain and serves as first vice president and national safety coordinator at the Air Line Pilots Association (ALPA). In a recent interview at the Skift Aviation Forum in Fort Worth, she said the union is advocating for pilots to “go back to our roots” and maintain strong manual-flying proficiency throughout their careers.

Morse said, “So the biggest thing is [getting] back to basics…We have to maintain a basic level of flying, a basic level of flying skills, and we have to continue to maintain those basics. This business about positive rate, gear up, [and] put on the autopilot is not a good idea. We have to keep flying the airplane so that we’re good at it.”

Boeing closes Spirit AeroSystems purchase in major supply chain realignment

Boeing has completed its takeover of Spirit AeroSystems. Under the $4.7 billion deal, Boeing re-acquires most of Spirit AeroSystems. Airbus picks up parts of Spirit in its supply chain. Operations in Subang, Malaysia, went to Composites Technology Research Malaysia, and the subsidiary Fiber Materials was sold earlier this year to Tex-Tech Industries. Portions of the Belfast, Northern Ireland, operations will continue as an independent subsidiary branded as Short Brothers.

Trump administration lets Southwest Airlines off the hook with a multimillion dollar waiver for 2022 holiday travel meltdown

In 2023, the Biden administration fined Southwest Airlines $140 million for the 2022 holiday travel meltdown. The US Department of Transportation has now waived the final $11 million installment of that fine. The DOT says Southwest has made worthwhile investments in its operations control center and “the Department is of the view that it is more beneficial for the flying public to give Southwest credit for significantly improving its on-time performance and completion factor.”

The 10-day schedule meltdown resulted in 17,000 canceled flights, roughly half of Southwest’s holiday season flight schedule. Southwest paid out $600 million in refunds and reimbursements to passengers who were affected. Add in additional labor costs and lost revenue, and the airline reported a $914 million after-tax loss.

Aviation News Follow-Up A320 Groundings – There Was No Solar Flare

In Visual Approach, Airplane Geeks co-founder Courtney Miller argues that the data does not support the case that the October 30, 2025, uncommanded altitude decrease of a JetBlue A320 was caused by solar radiation. Looking at proton flux data, Courtney says, “We are talking about high-energy protons traveling from the sun to Earth, penetrating the Earth’s protective magnetic field, and also penetrating the aircraft’s hardware shielding to deliver what’s called a Single-Event Upset (SEU). Another term you may have heard for it is a “bit flip”.

The proton flux usually arrives associated with a solar flare, but not always. NOAA tracks and reports these events. In the days leading up to the “intense solar radiation” that Airbus referenced as the potential issue in the JetBlue upset, there was no intense solar radiation.

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Pay-On-Delay Would Send Airfares Soaring, Says Transport Minister

The Australian Federal Transport Minister, Catherine King, told ABC Radio in Sydney that an EU-style “pay-on-delay” compensation scheme would drive up airfares in Australia. The federal government has proposed airline customer protections, and the Minister’s comments come after a consultation period ended. EU 261 requires that airlines pay passengers compensation for delays and cancellations within their control. King feels the Australian market is too small to sustain such a measure. “It is costly to administer compensation schemes. Those costs are generally passed on to passengers,” she said.

Fliers without a compliant ID will have to pay TSA $45 next year

The TSA says that starting in February 1, 2026, air travelers in the U.S. without a REAL ID will be charged a $45 fee. The initially planned $18 fee was raised after officials realized this identification program would cost more than anticipated. The fee applies to travelers 18 and older who are flying domestically without a REAL ID or other accepted form of ID. The non-refundable fee will be required to verify identity through the TSA Confirm.ID system.

Confirm.ID replaces TSA’s older manual “forgot my ID” procedures. It’s a more automated, technology‑assisted process that uses a traveler’s biographic and possibly biometric information to verify identity and screen against watchlists. Confirm.ID is meant as a last‑resort option for people who arrive at the checkpoint without a compliant ID, not as a routine substitute for REAL ID or a passport.

The fee can be paid online before arriving at the airport. Travelers can also pay online at the airport before entering the security line, but officials said the process may take up to 30 minutes.

Mentioned

From the FAA:

• PackSafe – Portable Electronic Devices Containing Batteries
• Lithium Batteries in Baggage

Hosts this Episode

Max Flight, Rob Mark, and our Main(e) Man Micah.