aerolab international

Behind every successful flight lies an unsung hero—a trusted service partner who ensures efficiency, precision and safety in every maintenance and repair operation. For airlines worldwide, that indispensable ally is Aero Lab International, synonymous with top-quality, comprehensive maintenance, repair and overhaul (MRO) services.

Setting Aero Lab apart is its expert team; a blend of contemporary aviation technology with deep regulatory expertise. Whether it’s adhering to the world’s strictest regulatory standards or orchestrating complex transcontinental logistics, Aero Lab’s professionals ensure aircraft remain flight-ready, no matter when and where they take flight.

Aero Lab’s commitment to aviation excellence continues beyond MRO services. It also supplies an extensive array of critical aircraft-related general and custom-modified parts and equipment, sustaining the reliability and safety of entire fleets. By consistently delivering superior solutions, Aero Lab has become a trusted partner for airlines around the globe, helping them soar to new heights of fleet efficiency and business success.

Sky-High Standard for Quality and Safety

Setting the benchmark for quality and safety, Aero Lab strictly adheres to manufacturers’ aircraft and engine maintenance manuals. This commitment ensures accuracy in every inspection. From routine 50-hour check-ups involving filter replacements and oil changes to intricate engine overhauls and hose replacements, every task is executed meticulously.

“Our competent and certified mechanics perform inspections and installations and present all of the appropriate paperwork to receive the airworthiness certification,” says Kenzo Colon, CEO.

Utilizing non-destructive testing methods, the company recertifies parts without replacements, delivering significant cost savings to clients.

Proactive planning is at the heart of Aero Lab’s inspection process. Before an aircraft arrives at the Yao Airport hangar in Japan, mechanics thoroughly review its inspection history. They identify components nearing time or usage limits and prepare for necessary replacements. With exceptional attention to detail, they detect even the smallest issues. Multiple quotes are sourced from reputable suppliers to present cost-effective options for clients before purchase approval.

To reduce downtime during repairs, Aero Lab maintains an extensive inventory of small hardware for quick replacements. It partners with third-party providers to arrange exchange services for more complex components, reducing lead times and expediting the overhaul process.

Beyond standard inspection and maintenance, Aero Lab offers specialized services to handle some of the most complex aircraft issues. It provides swift, expert intervention beyond standard maintenance in aircraft-on-ground (AOG) situations, which often result from crashes or severe malfunctions.

Going the extra mile, Aero Lab’s team travels worldwide to address emergencies. When incidents occur far from their base, they fly to the location to perform diagnostics and offer detailed quotes for necessary repairs. Depending on the severity of the damage, repairs are either completed on-site or the aircraft is transported to the Yao Airport hangar.
The hangar provides an ideal setting for collaborative operations. It benefits from a close-knit community where neighboring operators share resources. By exchanging tools and sharing plane parking spaces, Aero Lab enhances its capacity to perform repairs efficiently.

Aero Lab’s pilot shop is a vibrant hub that fosters community engagement. It is located near the hangar and caters to aircraft enthusiasts and airport staff, offering trinkets, clothing and essential aviation gear. The shop also provides a relaxed atmosphere where customers and employees can unwind with refreshments, making it a social cornerstone of the airport community.

Uncompromising on quality, Aero Lab meticulously manages its overhaul services. Although overhauls are not performed in-house, the company collaborates with repair stations approved by the Federal Aviation Administration (FAA), Transport Canada Civil Aviation (TCCA) and European Union Aviation Safety Agency (EASA). These partnerships ensure overhauled components come with original certification copies—a crucial requirement since the Japan Civil Aviation Bureau (JCAB) only accepts original or true certified copies—guaranteeing clients receive superior quality parts.

Aero Lab extends its resourcefulness by overcoming supply challenges through trusted networks.

“When parts require certification and all other avenues are exhausted, we rely on a trusted U.S. contact,” explains Colon. “We depend on this contact for older aircraft models with minimal parts in stock or lead times that last for months.”

Aero Lab consistently delivers results that surpass client expectations by maintaining high standards and leveraging strategic partnerships. Every repair transcends mere task completion—it’s a promise of safety and reliability.

From Japan to the World

Navigating the complexities of transporting aircraft overseas—whether for maintenance, an extended holiday or a sale—demands unparalleled expertise. Aero Lab streamlines this intricate process with its ferry flight service, ensuring a smooth journey from start to finish.

It uses container shipping for smaller planes to efficiently move them across oceans. Larger aircraft are ferried across the Pacific with precision and care by in-house pilots, leveraging a dedicated communications network.

Strategic planning defines each ferry route. The journey concludes at Aero Lab’s San Jose hangar, typically involving around 11 planned stops—including essential locations in Japan, Russia, Alaska, and across the United States. These stops are carefully selected for refueling, customs processing, parking and overnight stays, ensuring hassle-free transit.

Breaking industry boundaries that save clients critical time and resources, Aero Lab is the only Japanese company operating in Russian airspace and utilizing its airport facilities.

“By doing this, we save our customers hundreds of thousands of dollars and weeks compared to alternative routes through the Middle East, Europe and over the Atlantic,” says Colon.

The San Jose hangar is more than just a transit point—it’s a strategic center providing access to specialized parts often difficult to source in Japan. Aero Lab can secure FAA certification for these components in the U.S., streamlining clients’ maintenance and upgrade processes.

Beyond transportation, Aero Lab offers brokerage services for aircraft purchases, whether for resale or scrap. Leveraging a vast global network, it provides various options—from vintage models to modern business jets—tailored to each client’s specific needs. This personalized approach ensures clients find the ideal aircraft at competitive prices.

To elevate the purchasing experience, the company dispatches representatives to conduct thorough inspections of potential aircraft, ensuring they are fully operational and free from hidden damages. If transportation is required, Aero Lab arranges for the aircraft to be ferried directly to the client’s chosen location, providing a seamless acquisition experience.

Building trust and reliability at every operational step, Aero Lab has become a premier choice for clients navigating the complexities of the aviation industry.

Innovating fleet modernization with cutting-edge avionics upgrades, Aero Lab’s team excels in overhauling aircraft panels and replacing outdated wiring systems. As an authorized dealer for Garmin and BendixKing, the company provides advanced avionics at discounted rates. In 2020, Aero Lab received a Silver Award from Garmin for ranking in the top 15 percent of global sales.

Aero Lab’s innovation extends into aircraft design and interior and exterior customization. Exterior redesigns can range from minor aesthetic enhancements to full-scale repainting, while interior upgrades might involve new carpeting or a complete cabin overhaul. Clients can entrust the entire design process to Aero Lab or collaborate by providing their vision, with the company ensuring all modifications comply with relevant regulations.

A prime example of Aero Lab’s redesign expertise is transforming a standard passenger plane into a skydiving aircraft. This project required significant modifications, including retrofitting a vertical sliding door for safe and efficient jumps. Once the design was finalized, Aero Lab secured approval from JCAB and successfully converted the aircraft into a fully functional jump plane.

These innovations exemplify Aero Lab’s ability to blend creativity with engineering precision. As a leader in the field, the company is not just enhancing aircraft functionality, it’s redefining the very horizons of aviation.

Where Teamwork and Technology Elevate Aviation Standards

Under the visionary leadership of Colon and vice president Shogo Matsumoto, Aero Lab operates as a well-coordinated organization where each department harmoniously contributes to the company’s success.

Aero Lab’s work culture fosters innovation and professional growth. It invests heavily in its employees by covering training and licensing courses, providing them with the tools to continuously expand their expertise.

“We have mechanics and pilots of all ages,” says Colon. “Younger or less experienced ones receive mentorship from seasoned experts who have accumulated much experience.”

This spirit of mentorship and teamwork is mirrored in Aero Lab’s management structure, where the operations and mechanics departments work together to drive continuous improvement.

Led by Takumi Kitajima, the operations department is divided into sales, flight operations, and accounting. The sales team assists clients in purchasing aircraft, while the accounting team manages finances. The flight operations team, comprising fixed-wing and helicopter pilots, handles everything from test flights to specialized contracts with other companies.

On the technical side, the mechanics department, led by Shinichi Ozeki, is responsible for all mechanical work and parts procurement. From routine inspections to complex overhauls, they ensure that every aircraft meets the highest safety and performance standards. Utilizing the latest innovations, Aero Lab ensures that clients receive the most efficient and environmentally friendly parts on the market.

Aero Lab’s commitment to sustainability is evident in its resource-conscious practices. During maintenance, it relies on the latest illustrated parts catalog (IPC) and strives to overhaul parts whenever possible to reduce waste.

“We also keep a stock of our as-removed components to sell to companies with repair capabilities,” adds Colon. “All discarded metals, such as spray cans, nuts, bolts and other unusable aircraft components, are recycled.”

Looking to the future, it has partnered with IHI Aerospace to develop a suborbital spacecraft, aligning with Japan’s Ministry of Education, Culture, Sports, Science and Technology (MEXT) roadmap. While IHI Aerospace handles the airframe system and rocket engines, Aero Lab is responsible for building the structural components.
To support this ambitious initiative, Aero Lab has successfully conducted flight tests of a sub-scale winged experimental aircraft equipped with a rocket engine. These tests are designed to identify critical issues related to the suborbital flight of winged vehicles.

In addition to its space endeavors, Aero Lab is expanding its operations into aircraft charter services. While it does not currently own aircraft for charter, it has partnered with Air 7 Asia to provide charter and lease options. It has been brokering deals for Gulfstream G200 aircraft, which have garnered significant interest from clients seeking access to these luxurious jets in Japan.

Aero Lab’s growth trajectory is further bolstered by its ongoing auditing process as it aims to go public. If successful, it will become the first Japanese general aviation firm to be listed on the stock exchange. With an eye on the future, it is making waves in the general aviation industry with its comprehensive MRO services. Driven by its expert team, partnerships and forward-thinking vision, Aero Lab International is leading the way in Japan and beyond.