Global size of the aircraft MRO industry was estimated as USD 90.85 billion in 2024 and anticipated to grow with a CAGR of 8.65% from 2025 to 2035. Digital technologies are transforming aircraft MRO operations. Coupling state-of-the-art data analytics, AI, and machine learning technologies, predictive maintenance can minimize downtime and improve performance efficiency. Airlines and MRO service providers are increasingly adopting cloud-based systems to automate operations and enhance data access. This change not only saves costs but also facilitates better decision-making through real-time information. In addition, the use of digital twin technology enables more accurate simulations of aircraft performance, resulting in optimized maintenance schedules.
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Commercial Aircraft MRO Market Share
Global market players majorly focus on the development and expansion of their technologies and service portfolio to enhance business capabilities and cater to the rising demand. Strategic partnerships and enhancement of the product landscape are key initiatives in the global industry. Some of the key manufacturers include
- Airbus
- Boeing Company
- AAR Corporation
- Bombardier Inc
- Embraer S.A
- Delta TechOps
- General Dynamics Corp
- Hong Kong Aircraft Engineering Company (HAECO) Ltd
- GE Aviation
- Honeywell Aerospace
- Lufthansa Technik AG
- Rolls-Royce plc
- MTU Aero Engines AG
- Safran SA.
The Commercial Aircraft MRO Market research report includes in-depth coverage of the industry with estimates & forecast in terms of revenue in USD billion from 2017 to 2035 for the following segments
Market, By MRO Services
- Modifications
- Paintings
- Avionics Upgrades
- Interiors
- Others
- Airframe
- Components
- Wheels & Brakes
- Avionics
- Auxiliary Power Unit
- Fuel Systems
- Hydraulic Power
- Flight Controls
- Thrust Reversers
- Landing Gear
- Electrical
- Others
- Engine
- Airframe
Market, By Service Provider
- OEM
- Operator/Airline In-house
- Airline Third Party
- Independent
Market, By Aircraft
- Narrowbody
- Widebody
- Regional Jet
- Turboprop
Aircraft Type Insights
Narrow body segment recorded the highest share in revenues during 2024. With more people using airplanes in recent times, especially within the developing countries, narrow body aircraft fleet numbers in the operations of airlines all over the world have greatly grown. The greater flight hours from such aircraft means their routine upkeep and repairs intensify, increasing MRO opportunities. Also, new developments in narrow-body aircraft technology, including the implementation of more fuel-efficient engines and improved avionics systems, require expertise-specific maintenance skills. The requirements set by the government for safety standards and inspection from time to time further boost demand for MRO services within this category. Last but not least, the persisting tendency to outsource airlines’ maintenance processes to external MRO suppliers also spurred growth within the market.
The wide body segment is expected to anticipate the most rapid growth in the next few years. The demand for long-haul travel has prompted the development of wide-body fleets by airlines across the world. With these fleets reaching maturity, there arises a need for wide-ranging maintenance, repair, and overhaul services to make them airworthy and efficient enough to operate. Furthermore, technology advances in aircraft, including composite materials and advanced avionics, necessitate the need for expert maintenance and repair, and also further fueling demand for MRO services. Additionally, regulatory demands for safety and maintenance standards keep changing, and thus wide-body aircraft require constant updates and inspections.
Aircraft Generation Insights
The mid-generation segment held the maximum market revenue share in 2024. Predictive maintenance is emerging as a staple of MRO strategies for mid-generation aircraft. Through data analytics and sensor technologies, MRO providers can forecast maintenance requirements based on the operational history of the aircraft and real-time performance data. Predictive maintenance reduces unplanned downtimes and maximizes the lifespan of aircraft components, critically enhancing operational efficiency. Airlines are increasingly using predictive maintenance frameworks to improve safety and lower the cost of maintenance. Consequently, this trend is driving a shift from reactive to proactive maintenance strategies in the industry.
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U.S. Aircraft MRO Market Trends
The U.S. Aircraft MRO market is projected to grow at a CAGR during 2025-2030. The U.S. market is marked by its intense innovation focus, with cutting-edge technologies such as AI and machine learning spearheading improvements in operations. There is increased focus on the development of the workforce to fill the skills gap, making sure that technicians are capable of dealing with new-age maintenance issues. Partnership arrangements between airlines and MRO companies are also becoming more prevalent, creating combined maintenance solutions that maximize reliability and efficiency.
Europe Aircraft MRO Market Trends
The Europe MRO market for aircraft is likely to see substantial growth during the forecast period. Sustainability is a major trend in Europe as MRO companies react to regulatory pressures and public expectations for green practices. Partnerships between airlines, MROs, and OEMs are becoming increasingly common, enabling efficient maintenance processes and better service quality. The area also highlights adherence to tough safety standards, which has brought about the utilization of cutting-edge technologies such as digital twins and AI-based analytics.
