1 Global Aerospace MRO Market Insight Analysis
The global aerospace MRO market is valued at USD 106,772 million in 2024, with a CAGR of 5.90% from 2024 to 2033.
MRO stands for Maintenance, Repair, and Overhaul (MRO) in the aerospace Industry. Maintenance, Repair, Overhaul (MRO) in aerospace is the repair, service, or inspection of an aircraft or component. It is essentially all of the maintenance activities that take place to ensure safety and airworthiness of all aircrafts by international standards.
Maintenance – When work is done to ensure that the aircraft is in prime condition. There are no snags or failures observed, but the aircraft is serviced to simply keep it in functional readiness.
Repair – Aircraft often require repairs as they are complex machines with thousands of moving parts and software integrated. If an instrument panel doesn’t respond the way it should or there is a dent, an engine failure, or a broken window, repairs are carried out.
Overhaul – With a high wear and tear rate, most aircrafts undergo overhaul after a specific duration of flight operations. As a part of the overhaul process, aircrafts are dismantled piece by piece, each part inspected and reassembled. The overhaul process allows detailed inspection of all surface and internal parts of the plane and is a key element of the aircraft’s lifecycle management and enhancement.
Figure Global Aerospace MRO Market Size (M USD) and CAGR (2024-2033)
2 Aerospace MRO Market Growth Drivers and Restraints
Development of the air transport industry: The continued expansion of the global air transport industry is one of the key factors driving the growth of the aerospace MRO market. The rise of budget airlines has made air tickets more affordable, driving the growth of global air passenger traffic. As predicted by the International Air Transport Association (IATA), by the end of 2024, China will replace the United States as the world’s largest passenger market, with an estimated 817 million new passengers, which will greatly promote the development of the aircraft route maintenance market.
In terms of the number of flights, the number of flights performed by global airlines reached 38.9 million in 2019. Although it fell to 16.9 million in 2020 due to the epidemic, as the epidemic eased, from January to April 2022, the number of air passengers increased by 65% compared with the same period in 2021, the number of aircraft takeoffs increased by 30%, and the airline seat capacity increased by 32%, which brought more business opportunities to the aerospace MRO market.
Government support: The support of governments for aircraft MRO strategies provides a strong guarantee for market development. The U.S. Trade and Development Agency provided a feasibility study grant for the development of aircraft maintenance, repair and overhaul (MRO) facilities at Kotoka International Airport in Ghana; the Indian Ministry of Civil Aviation introduced a new MRO service policy to attract more investment by leasing land through public bidding and canceling the royalties collected by the airport authority; China’s “14th Five-Year Plan” civil aviation development plan emphasizes building a first-class civil aviation safety system, improving aviation maintenance capabilities, and forming a rationally distributed maintenance industry cluster. These policy measures are conducive to encouraging the development of the aviation and aerospace MRO industry.
Outsourcing trends: Airlines are increasingly inclined to outsource MRO services to reduce costs. Maintenance costs usually account for 40% of the cost structure of airlines. Outsourcing can transfer traditional indirect costs to maintenance suppliers, allowing airlines to focus on value-added businesses and support fleet growth and passenger volume. For example, many small and low-cost airlines have effectively reduced labor costs, training costs, and professional equipment procurement costs by outsourcing maintenance services, while also obtaining more professional maintenance services and improving aircraft on-time performance.
Shortage of professional talents: The aviation equipment maintenance industry has extremely high requirements for the quality and ability of professional talents. Professional talents usually need to graduate from professional aviation schools and undergo years of training. With the rapid development of the industry, the demand for high-end technical talents with rich experience continues to increase, and the competition for talents is becoming more and more fierce. The shortage of professional talents makes it difficult for companies to acquire and train talents, which in turn affects the company’s maintenance capabilities and service quality, and restricts the development of the market.
3 Technological Innovations in the Aerospace MRO Market
Automation and intelligent applications: Aircraft MRO companies actively adopt automated processes to reduce error rates and labor costs. Singapore Airlines Engineering Company invested in the establishment of an engine service department to study advanced aircraft engine maintenance technology; Korean Airlines used drone swarms to conduct full-body inspections of aircraft, significantly reducing inspection time.
In addition, advanced technologies such as the Internet of Things (IoT), big data analysis, artificial intelligence (AI), augmented reality (AR), robotics, and machine learning (ML) are widely used in the MRO industry. For example, IoT-based sensors can provide big data for optimizing condition-based monitoring (CBM), helping companies predict equipment failures in advance and avoid maintenance delays; AI-driven robots can perform regular maintenance tasks and reduce the need for engine disassembly maintenance; AR technology enables remote expert collaboration and maintenance personnel training, improving maintenance efficiency and quality.
Emerging technologies have great potential: Additive manufacturing (AM) technology has broad prospects in the MRO field. It can quickly and cost-effectively print strong, durable and lightweight replacement parts, significantly reducing inventory costs. For example, some companies use AM technology to manufacture customized parts for aircraft, improving the timeliness and flexibility of maintenance. At the same time, drones are increasingly being used in remote aircraft inspections, such as the RAPID system used by EasyJet and Thomas Cook Airlines, which enables automatic inspections of aircraft exteriors, improving the safety and efficiency of inspections.
Expanding business capabilities: Enterprises continue to expand their business capabilities through mergers and acquisitions. Spirit AeroSystems’ acquisition of Applied Aerodynamics not only expanded its MRO infrastructure in the region, but also gained new expertise, labor and business scope, enabling it to provide a wider range of maintenance services for more products, helping customers reduce costs and improve efficiency. The acquisition enables Spirit AeroSystems to perform composite material repairs on more aircraft models, including radomes, flight control components, etc.
Integrating resources and markets: StandardAero acquired Signature Aviation’s engine maintenance and overhaul business, integrating the resources of both parties. The new company has nearly 6,600 employees in 55 locations around the world, enhancing its competitiveness in the field of engine MRO services. Heston MRO acquired Jet Aviation’s Cairns MRO facility, expanding its capabilities in comprehensive heavy maintenance of regional aircraft and advanced avionics equipment repairs. These mergers and acquisitions and restructuring activities have promoted the integration of market resources, driven the centralized development of the industry, and changed the market competition landscape.
4 Global Aerospace MRO Market Size by Type
Engines are the heart of any aircraft, and their maintenance is critical for ensuring the safety and performance of flights. In 2024, the Engine MRO segment is projected to generate a revenue of $40,902 million USD. This represents approximately 38.31% of the total market share. The growth in this segment is driven by the increasing number of flights and the need for regular maintenance to ensure engine reliability. Airlines and aircraft operators are continuously investing in advanced engine technologies, which require specialized maintenance and overhaul services.
Airframe MRO involves the maintenance, repair, and overhaul of the aircraft’s structural components. This segment is expected to generate a revenue of $24,810 million USD in 2024, accounting for 23.24% of the total market share. The airframe is subjected to significant wear and tear due to the harsh conditions of flight, necessitating regular inspections and maintenance. The growth in this segment is influenced by the increasing fleet size and the need for compliance with stringent safety regulations.
Component MRO includes the maintenance of various aircraft components such as landing gears, avionics, and auxiliary power units. In 2024, this segment is projected to generate a revenue of $20,275 million USD, representing 18.99% of the total market share. The growth in this segment is driven by the increasing complexity of aircraft systems and the need for specialized maintenance to ensure their functionality. Component MRO services are essential for maintaining the reliability and efficiency of aircraft operations.
Line MRO refers to the maintenance activities that are performed during aircraft turnarounds, such as daily and weekly checks, minor repairs, and troubleshooting. In 2024, the Line MRO segment is expected to generate a revenue of $20,785 million USD, accounting for 19.47% of the total market share. This segment is crucial for ensuring that aircraft are in optimal condition for each flight. The growth in Line MRO is driven by the increasing number of flights and the need for quick and efficient maintenance to minimize downtime.
Table Global Aerospace MRO Market Size and Share by Type in 2024
Type | Market Size (M USD) 2024 | Market Share 2024 |
|---|---|---|
Engine | 40902 | 38.31% |
Airframe | 24810 | 23.24% |
Component | 20275 | 18.99% |
Line | 20785 | 19.47% |
5 Global Aerospace MRO Market Size by Application
Commercial aviation is the backbone of the global aerospace industry, driving the majority of the MRO market. In 2024, the Commercial Aerospace MRO segment is projected to generate a revenue of $90,938 million USD, accounting for approximately 85.17% of the total market share. This segment includes maintenance, repair, and overhaul services for commercial aircraft used in passenger and cargo transportation.
The Military Aerospace MRO segment is also a significant contributor to the global market. In 2024, this segment is expected to generate a revenue of $15,834 million USD, representing 14.83% of the total market share. Military MRO services include maintenance, repair, and overhaul of aircraft used by defense forces, including fighter jets, transport aircraft, and helicopters.
Table Global Aerospace MRO Market Size and Share by Application in 2024
Application | Market Size (M USD) 2024 | Market Share 2024 |
|---|---|---|
Commercial | 90938 | 85.17% |
Military | 15834 | 14.83% |
6 Global Aerospace MRO Market Size by Region
The United States is expected to lead the North American Aerospace MRO market with projected revenues reaching approximately $27620 million by 2024. This growth is attributed to the region’s mature aviation industry and the presence of major aerospace companies. The U.S. market’s growth is also supported by a strong focus on technological advancements in MRO services, which helps in maintaining the safety and efficiency of aircraft operations.
Europe is projected to maintain its significant share in the global Aerospace MRO market, with revenues estimated at $27291 million for 2024. Key contributing countries include Germany, the UK, France, and Italy. The region benefits from a well-established aerospace industry and a continuous demand for high-quality MRO services. The European market is also characterized by a strong emphasis on sustainability and environmental regulations, which drives innovation in MRO practices.
China is anticipated to witness rapid growth in the Aerospace MRO market, with revenues projected to reach $17,380 million by 2024.
The Middle East and Africa region is expected to see a steady increase in Aerospace MRO revenues, reaching $9,443 million by 2024. The growth in this region is driven by the expansion of air travel and the need for reliable maintenance services. Countries like the UAE and Qatar are investing in their aviation infrastructure, which includes developing MRO capabilities to support their growing fleets.
Latin America is projected to have Aerospace MRO revenues of $5,048 million by 2024. The region’s growth is supported by increasing air travel demand and the need for maintenance services. Brazil and Mexico are key markets in this region, with Brazil’s market growing due to its large domestic air travel market and Mexico’s due to its strategic location for international flights.
Figure Global Aerospace MRO Market Size (M USD) by Region in 2024
7 Global Aerospace MRO Market Analysis by Major Players
Lufthansa Technik
Company Profile
Lufthansa Technik is a leading provider of aircraft maintenance, repair, overhaul, and modification services for civil aircraft. Established in 1995, the company operates globally and is headquartered in Hamburg, Germany. Their extensive technical experience and profound knowledge of operating fleets make them a trusted name in the industry.
Business Overview
Lufthansa Technik offers a comprehensive range of services tailored to meet the needs of commercial and VIP aircraft operators. Their services include line maintenance, engine overhauls, airframe maintenance, and component repairs. The company’s long heritage in the airline business has endowed them with extensive technical expertise, enabling them to provide customized solutions for various aircraft types. They also offer engineering services such as customized task cards, warranty management, transition management, consulting, and cabin modifications.
Products Offered
Lufthansa Technik provides a wide array of MRO services, including line maintenance, engine overhauls, airframe maintenance, and component repairs. Their line maintenance services are available at international and German stations, ensuring aircraft are in optimal condition for flight. Engine overhauls cover a variety of engine types, ensuring engines are maintained to the highest standards. Airframe maintenance includes heavy and light maintenance checks, such as C and D checks, as well as cabin modifications and composite repairs. Component repairs focus on maintaining and repairing aircraft components to ensure reliability and efficiency.
AFI KLM E&M
Company Profile
AFI KLM E&M is a major multi-product MRO provider with a global presence. Established in 2008, the company is headquartered in Paris, France. They offer comprehensive technical support ranging from engineering and line maintenance to engine overhaul, aero structure, and fan thrust reverser support, backed by a powerful logistics network.
Business Overview
AFI KLM E&M provides a wide range of MRO services for commercial aircraft. Their offerings include airframe maintenance, engine overhauls, component repairs, and line maintenance. The company’s extensive experience in the aviation industry allows them to deliver high-quality services tailored to the specific needs of their customers. They also offer engineering support, including customized task cards, warranty management, and transition management. Their global network of facilities ensures that they can provide timely and efficient services to airlines worldwide.
Products Offered
AFI KLM E&M offers a comprehensive suite of MRO services, including airframe maintenance, engine overhauls, component repairs, and line maintenance. Their airframe maintenance services cover heavy and light maintenance checks, as well as cabin modifications and composite repairs. Engine overhauls ensure engines are maintained to the highest standards, while component repairs focus on maintaining and repairing aircraft components to ensure reliability and efficiency. Line maintenance services are available at over 100 outstations worldwide, providing quick and efficient turnaround times for aircraft in transit.
MTU Aero Engines
Company Profile
MTU Aero Engines is a leading manufacturer of commercial and military aircraft engine components and spare parts. Established in 1913, the company is headquartered in Munich, Germany. They specialize in the development, production, and maintenance of aircraft engines.
Business Overview
MTU Aero Engines is renowned for its expertise in aircraft engine maintenance, repair, and overhaul (MRO) services. The company offers a wide range of services, including engine overhauls, component repairs, and maintenance services for both commercial and military aircraft. Their decades of experience in the industry have enabled them to develop innovative repair techniques and technologies that ensure high engine availability and reduced costs. MTU Aero Engines also collaborates with major aircraft manufacturers to provide comprehensive MRO solutions.
Products Offered
MTU Aero Engines provides a comprehensive suite of MRO services for aircraft engines. Their offerings include maintenance, repair, and overhaul services for a variety of engine types, ensuring that engines are maintained to the highest standards. They also offer component repairs, leveraging their expertise in advanced repair techniques to restore damaged components and extend their operational life. Additionally, MTU Aero Engines provides maintenance services for military aircraft engines, ensuring that these critical assets remain in optimal condition. Their services are backed by a commitment to innovation and continuous improvement, ensuring that customers receive the highest quality of service.