IAI commences B777-300ERSF P2F conversions in North America
IAI first announced its partnership with Ascent Aviation Services in September 2023, with plans to establish two Boeing 777-300ERSF conversion lines at Marana, Arizona, and begin operations in 2024.
Israel Aerospace Industries (IAI), Ascent Aviation Services and World Star Aviation today announced the commencement of Boeing 777-300ERSF passenger-to-freighter (P2F) conversions in North America. The first Boeing 777-300ER passenger aircraft from World Star Aviation’s portfolio has arrived at Ascent’s newly expanded Pinal Air Park campus in Marana, Arizona, for conversion.
The aircraft, registered N755WS (MSN 33755), is an 18-year-old Boeing 777-300ER that Taiwan's EVA Air previously operated as B-16712. First delivered to EVA Air on July 24, 2008, the aircraft was withdrawn from passenger service in June 2026 and arrived at Marana on July 29 for conversion.
Ascent’s Marana facility will serve as the North American conversion site for IAI’s 777-300ERSF programme, forming part of IAI’s global conversion network. "As cargo operators seek to maximise fleet value and meet growing long-haul freight demand, P2F conversions have become one of the fastest-growing segments in the commercial aviation aftermarket," the release reads.
IAI launched its Boeing 777-300ERSF passenger-to-freighter conversion programme, known as the ‘Big Twin’, in 2019 in partnership with GECAS, which later became part of AerCap. The first aircraft entered conversion in 2021, and the programme received certification from US and Israeli aviation authorities in September 2025. As of October 2026, IAI has completed and delivered 11 converted aircraft, with customers and operators including Kalitta Air, Fly Meta, Challenge Group and Emirates SkyCargo. Kalitta Air, the launch operator, received seven aircraft. In July 2026, IAI reported five additional aircraft undergoing conversion. The company is expanding production beyond its Tel Aviv facility in Israel through conversion partnerships with Sharp Technics K in Incheon, South Korea, Etihad Engineering in Abu Dhabi, UAE, and Ascent Aviation Services in Marana, Arizona, US, where the first aircraft from World Star Aviation arrived for conversion in October 2026.
Guy Bar Lev, IAI’s President and CEO, says, “Our vision is to shape the future of aviation by turning engineering innovation into lasting value for our customers. Passenger-to-freighter conversions are a key part of that vision, extending the productive life of aircraft and helping airlines adapt to changing market needs. Establishing a conversion presence in North America advances our long-term strategy to strengthen IAI’s position in the global commercial aviation market.”
IAI first announced its partnership with Ascent Aviation Services in September 2023. As part of the agreement, Ascent Aviation Services will operate two parallel Boeing 777-300ERSF conversion lines. The expansion is expected to create hundreds of highly skilled aviation jobs in Southern Arizona while reinforcing Marana’s position as one of North America’s fastest-growing aerospace and aviation hubs. By combining IAI’s certified conversion technology with Ascent’s extensive MRO infrastructure and widebody aircraft expertise, the facility expands global conversion capacity while providing customers with greater flexibility and support in the North American market.
Yaacov Berkovitz, EVP and GM of IAI Aviation Group, says, “The launch of Boeing 777-300ERSF conversions in North America marks an important milestone for IAI’s global conversion programme. Together with Ascent Aviation Services, we are expanding production capacity and bringing our conversion capabilities closer to customers in the region. World Star Aviation has played a key role in making this milestone possible, and we deeply appreciate their commitment, the work they have invested in bringing the first aircraft to Marana, and their confidence in IAI’s technology. This collaboration brings together the expertise and dedication of all three companies to support cargo operators worldwide.”
IAI’s Boeing 777-300ERSF is the world’s first and only certified Boeing 777-300ER passenger-to-freighter conversion programme. "The arrival of the first World Star Aviation aircraft demonstrates continued market confidence in the programme while expanding IAI’s ability to support customers as demand for widebody freighter conversions continues to grow," the release reads. In September 2025, IAI secured an agreement with World Star Aviation to convert a Boeing 777-300ER passenger aircraft into a freighter under its 777-300ERSF programme, with an option for a second conversion.
David Querio, CEO of Ascent Aviation Services, says, “The arrival of our first Boeing 777-300ER conversion aircraft marks an exciting new chapter for Ascent Aviation Services. This aircraft represents far more than the start of a single project – it marks the beginning of a long-term partnership with IAI and the first of many Boeing 777-300ERSF passenger-to-freighter conversions that will take place here in Marana. As the demand for cargo conversions continues to grow across the aviation industry, Ascent is proud to be at the forefront of this expanding market with world-class facilities, exceptional talent, and a commitment to operational excellence.”
The launch follows the completion of two new cutting-edge, 90,000-square-foot widebody hangars purpose-built to support IAI’s global Boeing 777-300ERSF conversion programme. The $70 million investment triples hangar capacity at Ascent’s Marana facility, significantly expanding the company’s heavy maintenance and widebody aircraft modification capabilities, further positioning Southern Arizona as a premier destination for next-generation freighter conversions.
Yoyo Allalouf, Partner, World Star Aviation, says, “We chose IAI’s 777-300ERSF P2F programme because we believe it is the strongest 777 P2F programme available at this most critical of times for 777 passenger-to-freight conversion production. Ascent’s Marana facility gives us the capacity and quality standards we look for as we grow our freighter portfolio. Decisions like this one are how we manage value for our investors across the cycle – backing the right platform, the right technology and the right execution partner. We’re glad to see this aircraft lead the way for the programme in North America.”
Garreth Slevin, Partner, World Star Aviation: “WSA’s history with IAI in widebody P2F programmes dates back to the 1990s and the Boeing 747-200 P2F programme. IAI’s dominance in the widebody P2F space, demonstrated by its Boeing 747 and 767 programmes, together with our long-standing relationship, underpinned our decision to choose IAI for the 777-300ERSF. We’re proud to continue that partnership with Ascent as the programme launches in North America.”
