After much delay, IAI secures 777-300ERSF STC

More than five years since launch, IAI has obtained certification from the FAA and the Civil Aviation Authority of Israel for its 777-300ERSF program, the first 777 freighter conversion project to receive an STC. The FAA and the Civil Aviation Authority of Israel granted the STC to IAI today, IAI told Cargo Facts . [caption id="attachment_57291308" align="aligncenter" width="2560"] Unit 32785 is now at Kalitta Air's facility in the airline's colors. (Photo/Cargo Facts)[/caption] The STC paves the way for IAI to redeliver the first 777-300ERSFs it has completed to AerCap, and for the lessor to start delivering them to lessees ahead of entry into service. The launch operator is Kalitta Air. One of AerCap’s 777-300ERSFs (32785, ex-Emirates) is at the carrier’s facility in Oscoda, Mich. (OSC). That 2005-vintage aircraft has been in the United States since November 2024 for certification tests with the FAA for its Collins Aerospace cargo-loading system . IAI told Cargo Facts in March that it had completed its certification flights with the FAA in the U.S. using the 2005-vintage prototype (32789, ex-Emirates). That aircraft flew back to Tel Aviv (TLV) that month but will also join Kalitta Air. The third, fourth and fifth 777-300ERSFs (32787, 32792 and 32791) that IAI has completed and test flown all have Kalitta Air registrations. Certification delays Since launching the 777-300ERSF Big Twin program with AerCap — then GECAS — as a co-investor in 2019, IAI has had to continually push its certification timeline to the right because of unforeseen events including the pandemic, the Israel-Hamas war, Alaska Airlines Flight 1282 and the NTSB and FAA investigations into Boeing’s safety lapses. Even in early 2024, Kalitta Air told Cargo Facts that it hoped to receive its first of at least seven 777-300ERSFs on order from AerCap by the end of that year. Still, obtaining the STC represents a major hurdle cleared for IAI, which will soon also see its product join the fleets of Fly Meta and Challenge Group as part of lease deals with AerCap. Challenge Group still expects its first of two 777-300ERSFs from AerCap by yearend, the group told Cargo Facts . The 2007-vintage aircraft (32795, ex-Emirates) arrived at TLV for conversion in December 2024. Challenge also sent its own 777-300ER feedstock aircraft (38284, ex-EgyptAir) to TLV in April for conversion with IAI and expects to take redelivery around April 2026, the group said. Ramping up 777 conversions With certification in hand, IAI will soon begin new conversion sites in addition to its own facility at TLV: Ascent Aviation Services in Marana, Ariz. (MZJ); Etihad Engineering in Abu Dhabi (AUH); and Sharp Technics K in Seoul (ICN). Meanwhile, Mammoth Freighters expects to begin certification flights with its 2009-vintage 777-200LRMF prototype (29742, ex-Delta Air Lines) this month and will seek to add its 777-300ERMF conversion as an amendment to the 777-200LRMF STC in Q1 2026. Additionally, Kansas Modification Center is preparing to make the cargo door cutout on its prototype 777-300ERCF. Register here for Cargo Facts ’ upcoming free webinar, “Air cargo route networks: Strategies for improved results and greater efficiencies,” on Tuesday, Sept. 16, at 11 a.m. ET. Cargo Facts Symposium, the quintessential event for stakeholders and key leaders in the global freighter and air cargo industries, will take place Oct. 22-24 at the Grand Hyatt in Nashville . Learn more and register today to take advantage of the early-bird rate before Sept. 5.

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