IAI’s 777-300ERSF freighter conversion program, known as the "Big Twin," has rapidly gained global momentum with over 50 orders and options from leading cargo operators like AerCap, Emirates, and Challenge Group. Over the past year, IAI completed certification testing, prepared the first five aircraft for delivery, and expanded conversion capabilities globally—including sites in Tel Aviv, Abu Dhabi, the USA, and South Korea. The aircraft offers near-747 capacity with 21% better fuel efficiency, making it a leading replacement for aging freighters. Backed by a strong regulatory record, full lifecycle support services, and a growing portfolio that includes the upcoming A330-300P2F program, IAI is solidifying its position as a frontrunner in the freighter conversion market.

1. What is the current outlook for IAI’s 777-300ERSF freighter conversion program? How has the program progressed over the past year?

Rafi Matalon- The 777-300ERSF program continues to gain significant traction, both technically and commercially. Over the past year, we have completed full-scale certification flight testing program, achieved major regulatory milestones, and prepared the first 5 converted aircraft for delivery to our launch customer, AerCap.

Additional units are now in advanced stages of conversion. The market response has been overwhelmingly positive. With over 50 aircraft orders and options secured from top-tier customers—including AerCap, Emirates, Challenge and Cargo jet—the Big Twin is clearly addressing a pressing need in the global air cargo market. Its performance, payload capacity, and cost efficiency make it the most compelling replacement for aging platforms such as the 747-400F and MD-11.

2. Could you share insights into the timeline from conversion start to delivery for the 777- 300ERSF?

Rafi Matalon- A standard 777-300ERSF conversion—from induction to redelivery—takes approximately 4.5 to 5 months, depending on the aircraft’s condition and the customer's specific requirements. To support growing demand, IAI has scaled its global conversion footprint. In addition to our primary facility in Tel Aviv, we’ve launched and expanded partnerships with Etihad Engineering MTO in Abu Dhabi, and we are developing additional capacity in Asia and North America, including upcoming conversion lines in the USA and in South Korea.

This multi-site strategy ensures scalability and accelerated turnaround times for our global customers.

3. How does the 777-300ERSF program compare to other freighter conversions in terms of order volume?

Rafi Matalon- The 777-300ERSF is currently one of the most in-demand widebody freighter conversions on the market. With over 50 firm orders and options, the program continues to generate traction from major leasing companies and cargo carriers worldwide. Its operational economics—offering near-747 volume at a significantly lower cost—make it a category leader. The 777-300ER offers greater volumetric capacity, lower fuel burn per ton, and higher market appeal, especially for operators replacing legacy widebodies.

4. How is IAI integrating sustainability and environmental considerations into the 777- freighter conversion?

Rafi Matalon- Sustainability is a key component of IAI’s conversion philosophy. The 777-300ERSF helps reduce environmental impact. It offers a fuel burn improvement of up to 21% per ton compared to older quad-engine freighters like the 747-400F and MD-11, resulting in lower emissions per kilo carried.

Throughout the conversion process, we implement eco-friendly practices, including responsible material handling, waste minimization, and recycling of structural components. This aligns with IAI’s broader commitment to supporting global aviation’s sustainability goals.

5. How has IAI worked with aviation authorities worldwide to ensure smooth certification and acceptance?

Rafi Matalon- IAI has over 40 years of experience in developing and certifying freighter conversions across multiple platforms. For the 777-300ERSF, we collaborated closely with the Israeli Civil Aviation Authority (CAAI) during the STC process, and the aircraft has successfully completed structural and flight testing.

The aircraft has also undergone FAA certification testing, with final VSTC approval expected shortly. Next, we will progress toward validation to our STC from EASA and CAAC, which we anticipate obtaining by the end of this year or the beginning of the next. Our proven regulatory track record ensures a smooth path to global acceptance for all converted aircraft.

6. What kind of aftermarket support and maintenance services does IAI provide for converted 777 freighters?

Rafi Matalon- IAI provides a full suite of lifecycle support services to ensure long-term operational performance of converted aircraft. This includes Airframe MRO services through our global Aviation Group; Engineering support and technical assistance; Entry-into-service and 24/7 AOG Engineering support. We also offer a Crew and maintenance training programs to ensure smooth entry to service. Our deep expertise in aircraft modification and OEM-level engineering ensures that operators receive comprehensive support from delivery through the full operational life of the freighter.

7. How does IAI plan to position itself in light of emerging freighter conversion trends, such as those involving newer widebody aircraft?

Rafi Matalon- IAI continues to lead the global freighter conversion market by focusing on platforms that combine technical viability with strong market demand.

The 777-300ERSF is a clear example—a next-generation solution that meets long-haul, high- volume cargo needs with superior economics.

Beyond the 777-300ERSF, IAI is actively advancing the A330-300P2F conversion program, which is on track for STC certification in the first half of next year.

The A330-300 freighter will offer the best-in-class performance in the medium widebody segment and is designed to meet growing demand from regional and intercontinental operators alike. Together, these programs reflect IAI’s strategic commitment to providing a comprehensive portfolio of widebody freighter conversions supported by decades of experience, robust global infrastructure, and an unrelenting focus on quality and innovation.