Global Aircraft MRO Market Size, Share, Growth, Trends, and Global Industry Analysis: By Service (Engine Overhaul, Airframe Maintenance, Line Maintenance, Modification, and Components), By Aircraft Type (Narrow-Body, Wide-Body, Regional Jet, and Others), By Aircraft Generation (Old Generation, Mid Generation, and New Generation), By Organisation Type (Airline MRO, Independent MRO, and Original Equipment Manufacturer MRO), By End User (Airlines, Aircraft Operators, MRO Service Providers, Original Equipment Manufacturers, and Government and Military), and Region Forecast 2020-2031

Aircraft MRO Market size was valued at US$ 91,224.8 million in 2024 and is projected to reach US$ 133,585.8 million by 2031 at a CAGR of 5.6% from 2025-2031. Moreover, the U.S. Aircraft MRO Market is projected to grow significantly, reaching an estimated value of US$ 41,678.8 Million by 2031. Aircraft MRO (Maintenance, Repair, and Overhaul) is the comprehensive set of services and procedures performed to ensure the continued airworthiness, performance, and safety of an aircraft. The market is experiencing steady growth, primarily driven by the expansion of the global aircraft fleet and rising air traffic, especially in emerging economies.

Increased aircraft utilization and the extension of aircraft service life are generating consistent demand for maintenance, repair, and overhaul services. Airlines are also focusing on cost-effective MRO strategies to remain competitive, further supported by regulatory mandates and the growing use of technologies such as AI and IoT for predictive maintenance. A key trend shaping the market is the rising need for aftermarket services and aging fleet support, as older aircraft require more frequent servicing. Additionally, the industry is witnessing a shift toward outsourcing and the formation of strategic partnerships to enhance global reach and operational efficiency. On the opportunity front, the adoption of digital technologies offers vast potential for smarter, more predictive maintenance models that reduce costs and downtime.

However, the market faces challenges due to the high cost and complexity of advanced technologies, a shortage of skilled professionals, and integration issues. Regulatory differences, geopolitical uncertainties, and supply chain disruptions further impact growth. Despite these restraints, innovation, digital transformation, and expanding global air traffic position the MRO sector for sustainable long-term development.

Facts & Figures

• Expansion of Global Aircraft Fleet and Rising Air Traffic: As air travel demand grows, especially in emerging markets, airlines are expanding their fleets to meet passenger and cargo needs. For instance, IndiGo’s plan to build a ?1,100 crore MRO facility in Bengaluru (May 2025) supports fleet expansion and the need for in-house maintenance capacity.
• Aging Aircraft and Lifecycle Extension: Many airlines are operating aircraft beyond their traditional lifespan to delay the purchase of new, expensive models, increasing the need for frequent MRO services. For instance, GE Aerospace’s $1 billion investment in engine repair shops aims to support LEAP engine servicing for aging fleets and reduce turnaround time.
• Increasing Outsourcing by Airlines: Airlines are outsourcing MRO operations to specialized third-party providers to cut costs, focus on core operations, and access advanced technology. For instance, IndiGo and Air India Express signed MRO deals with Turkish Technic (Feb 2025) for redelivery checks and landing gear overhauls.
• Adoption of Predictive Maintenance and Digital Solutions: MRO providers are adopting AI, IoT, and big data to predict failures and schedule maintenance more efficiently. For instance, Air Serbia implemented AMROS’s AI-based platform LISA (April 2025) to digitize maintenance records and improve compliance and efficiency

Key Developments:

• In July 2025, A joint venture between Dassault Aviation and Reliance will manufacture Falcon business jets in Nagpur, positioning India as a global aerospace hub and supporting local MRO capabilities.
• In June 2025, ITP Aero secured a €100 million contract to maintain Pratt & Whitney GTF engines, adding a new global service center in Spain and creating 200 jobs.
• In May 2025, IndiGo plans to build a 1,100?cr MRO facility in Bengaluru.
  IndiGo and BIAL signed an MoU for a 31-acre MRO campus capable of servicing wide- and narrow-body aircraft, expected to generate 750+ jobs.
• In May 2025, Samtel Avionics and ATSC partnered on avionics repair and overhaul services for Su?30MKM fighter jets, enhancing defence MRO capabilities.
• In February 2025, IndiGo and Air India Express signed MRO deals with Turkish Technic. Turkish Technic will conduct redelivery checks and landing gear overhauls for IndiGo and Air India Express fleets, enhancing component and landing gear servicing.

Aircraft MRO Market Segmentation:

Based on the service:

• Engine Overhaul
• Airframe Maintenance
• Line Maintenance
• Modification
• Components

Engine overhaul holds the largest market share in the market, as engines are the most critical and expensive components of an aircraft, requiring regular inspection, servicing, and full overhauls to ensure optimal performance and safety. The increasing number of flight hours and the extended service life of aircraft have significantly raised the frequency of engine maintenance cycles. Additionally, advancements in engine technology and rising demand for fuel-efficient engines have increased the complexity and cost of overhauls, boosting this segment’s revenue. In contrast, the modification segment holds the lowest market share, as it is typically optional and less frequently performed than essential maintenance tasks.

Based on the aircraft type:

• Narrow-Body
• Wide-Body
• Regional Jet
• Others

Based on aircraft type, narrow-body aircraft hold the largest market share in the market. This dominance is due to their extensive use in short- and medium-haul routes, especially by low-cost carriers operating at high frequency. With a significantly larger global fleet and higher utilization rates, narrow-body aircraft require more frequent line maintenance, engine checks, and component replacements. Their widespread use in domestic and regional markets further amplifies the demand for timely and efficient MRO services. On the other hand, regional jets account for the smallest share, as they operate fewer flights, have shorter routes, and are often maintained under smaller-scale MRO contracts.

Based on the aircraft generation:

• Old Generation
• Mid Generation
• New Generation

Based on aircraft generation, mid-generation aircraft hold the largest market share in the market. These aircraft form the backbone of many airline fleets and require consistent maintenance due to their active usage and aging components, yet they are not old enough to be retired. They strike a balance between operational efficiency and cost, making them prime candidates for engine overhauls, structural inspections, and component replacements. Their longer time in service compared to newer models also increases the frequency of MRO activities. In contrast, new-generation aircraft hold the smallest share, as they are built with advanced materials and systems that require less frequent maintenance in the initial years of operation.

Based on the organisation type:

• Airline/Operator MRO
• Independent MRO
• Original Equipment Manufacturer (OEM)MRO

Independent MRO providers hold the largest market share in the market. They offer flexible, cost-effective, and specialized services to a wide range of airline clients, including low-cost carriers and regional operators. Their global presence, scalability, and ability to serve multiple aircraft models make them highly preferred, especially in regions lacking in-house airline capabilities. Independent MROs also benefit from increased outsourcing by airlines aiming to reduce costs and focus on core operations. On the other hand, OEM MRO providers hold the smallest share, as their services are typically limited to their own manufactured components or aircraft models, resulting in a narrower client base.

Based on the end user:

• Airlines
• Aircraft Operators
• MRO Service Providers
• Original Equipment Manufacturers (OEMs)
• Government and Military

Airlines represent the largest end-user segment in the market, as they require continuous, comprehensive maintenance to ensure the safety, reliability, and efficiency of their operational fleets. Airlines conduct frequent line maintenance, major overhauls, and component replacements to comply with rigorous regulatory and safety standards. At the other end, government and military users hold the smallest market share, as their fleets are smaller, specialized, and maintained under defence-specific contracts and protocols.