Aircraft Heavy Maintenance Visits Market Size:
Aircraft Heavy Maintenance Visits Market size is estimated to reach over USD 5,644.56 Million by 2032 from a value of USD 4,079.44 Million in 2024 and is projected to grow by USD 4,192.44 Million in 2025, growing at a CAGR of 4.4% from 2025 to 2032.
Aircraft Heavy Maintenance Visits Market Scope & Overview:
Aircraft heavy maintenance visits refer to an extensive maintenance check that is conducted on an aircraft, which typically occurs at scheduled intervals. These checks are more comprehensive and usually require a longer time period as compared to routine aircraft maintenance. Moreover, scheduled heavy maintenance visits ensure safety, airworthiness, and operational reliability of the aircraft. Aircraft heavy maintenance visit involves thorough examinations, structural inspections, component replacements, and system upgrades.
Aircraft Heavy Maintenance Visits Market Dynamics - (DRO) :
Key Drivers:
Rising air travel activities is propelling the aircraft heavy maintenance visits market growth
The global air travel industry continues to grow as airlines are expanding their fleets, owing to an increase in commercial flight activities. Moreover, the rise in air travel activities propels the aircraft heavy maintenance visit market by necessitating more frequent and comprehensive maintenance services, driven by increased regulatory scrutiny, fleet extension, aging aircraft, safety concerns, and operational reliability demands.
- For instance, according to International Air Transport Association (IATA), the global air passenger traffic gained significant momentum and increased by 36.9% in 2023 as compared to 2022. Additionally, according to the IATA, European airlines’ full year traffic increased by 22% in 2023 in comparison to 2022.
Hence, the rising air travel activities is increasing the need for aircraft maintenance visits to ensure the reliability, safety, and compliance of commercial aircraft operations, in turn proliferating the aircraft heavy maintenance visits market size.
Key Restraints:
High cost of maintenance is restraining the aircraft heavy maintenance visits market
The high cost of maintenance is a critical restraining factor in the aircraft heavy maintenance visits (HMV) market due to the extensive labor, specialized equipment, and stringent regulatory compliance required for these operations. HMVs involve comprehensive inspections, repairs, and overhauls that necessitate significant downtime, which can disrupt fleet utilization and operational efficiency. Additionally, the reliance on skilled technicians, the need for original equipment manufacturer (OEM) parts, and adherence to aviation safety standards further inflate costs. The expense is compounded by advancements in aircraft technology, which require specialized diagnostics and tooling, as well as escalating costs for materials and replacement components. These factors collectively create financial pressure on airlines, especially low-cost carriers, limiting their ability to invest in routine HMVs.
- For instance, IATA's Maintenance Cost Technical Group (MCTG), an airline volunteer group which gathers and analyzes maintenance cost, reported an overall direct maintenance cost of approximately USD 10.11 billion for their active aircraft in 2022. Additionally, the average maintenance cost reached USD 326 million per airline and USD 2.9 million per aircraft. Further, according to IATA, aircraft engines and components remained the highest cost segments in 2022, accounting for 37% and 26% of the overall maintenance costs in 2022.
Therefore, high cost associated with aircraft maintenance services is hindering the aircraft heavy maintenance visits market expansion.
Future Opportunities :
Increasing expenditure on aircraft MRO (maintenance, repair, and operation) activities is expected to drive the aircraft heavy maintenance visits market opportunities
Airlines are investing heavily in aircraft MRO activities due to the prevalence of multiple safety standards and stringent regulations from aviation authorities worldwide. Airlines are compelled to spend more on MRO activities, which include heavy maintenance visit, to ensure compliance with mandatory aircraft checks and inspections for facilitating operational safety and maintaining an airline's reputation. As airlines continue to focus on maximizing operational safety and performance, heavy maintenance visits will form a crucial component of their MRO strategies, in turn providing lucrative aspects for market growth.
- For instance, according to the International Air Transport Association (IATA), the total spending on commercial aircraft MRO activities in North America and European region was valued at approximately USD 26 billion and USD 24 billion respectively in 2023.
Thus, as per the analysis, rising expenditure on aircraft MRO activities is projected to increase the demand for aircraft maintenance visits to ensure operational safety and performance of the aircraft. The above factors are expected to boost the aircraft heavy maintenance visits market opportunities during the forecast period.
Aircraft Heavy Maintenance Visits Market Segmental Analysis :
By Service Type:
Based on service type, the market is segmented into airframe maintenance, engine maintenance, and other component maintenance.
Trends in the Service Type:
- Increasing adoption of airframe maintenance services for safety assurance and increased operational efficiency.
- Rising trend towards utilization of engine maintenance services to extend the operational life of an engine and reduce unplanned downtime.
The airframe maintenance segment accounted for the largest revenue share of 41.68% in the total aircraft heavy maintenance visits market share in 2024.
- Airframe maintenance services refer to the comprehensive procedures and activities focused on the upkeep, repair, and assessment of an aircraft's airframe, which includes the fuselage, wings, tail section, and structural components of the aircraft.
- Airframe maintenance services involve routine inspections, modifications, repairs, cleaning, and functional checks to ensure that the airframe is safe, reliable, and compliant with aviation regulations.
- Moreover, conducting periodic airframe maintenance services offers a range of benefits including safety assurance, extended aircraft lifespan, increased operational efficiency, and others.
- For instance, AAR Corporation is an independent maintenance, repair, and overhaul (MRO) provider in North America that offers airframe heavy maintenance services in its service offerings. The company’s heavy maintenance services primarily include airframe upgrades, on-wing flight control inspections, on-wing component inspections, structural inspections, component replacement, structural and composite repairs, and other related services.
- According to the analysis, the rising advancements associated with airframe maintenance services are driving the market.
The engine maintenance segment is anticipated to register fastest CAGR growth during the forecast period.
- Engine maintenance services aim to upkeep, repair, and optimize the performance of an aircraft's engines.
- Engine maintenance services are critical for ensuring the safety, reliability, and efficiency of the entire aircraft, as engines are among the most vital components of an aircraft system.
- Additionally, conducting scheduled engine maintenance provides several benefits including enhanced engine performance, extended engine lifespan, minimized downtime, and increased reliability among others.
- For instance, Airline Support Baltic offers a range of aircraft maintenance services including engine maintenance in its service offerings. The company’s engine maintenance services include complete engine diagnostics for troubleshooting, repair of individual assembly units of the engine system, performance of overhaul repair of the engine, restoration of the engine, and periodic maintenance of the aircraft engine.
- Thus, increasing advancements related to aircraft engine maintenance services are anticipated to drive the market during the forecast period.
By Aircraft Type:
Based on aircraft type, the market is segmented into fixed wing and rotary wing.
Trends in the aircraft type:
- Increasing adoption of fixed wing aircraft, attributing to its higher speed capabilities, longer flight range, and, greater payload capacity.
- Factors such as rising investments in air defence platform and technological advancements in aircraft manufacturing are major determinants for driving the segmental growth of fixed wing and rotary wing aircraft.
Fixed wing segment accounted for the largest revenue in the overall aircraft heavy maintenance visits market share in 2024.
- Fixed wing aircraft refers to a type of aircraft with wings that remain stationary while generating the aircraft's lift.
- Fixed wing aircraft is capable of flight using wings that produce lift generated by the aircraft's forward air speed and the shape of the wings.
- Moreover, fixed wing aircraft offers a range of benefits including higher speed capabilities, longer flight range and endurance, greater payload capacity, improved stability in turbulent weather conditions, along with relatively lower maintenance and operational cost among others.
- For instance, in November 2022, Aurora Flight Sciences launched its new fixed-wing eVTOL (electric vertical take-off and landing) aircraft that is specifically designed for airborne ISR (intelligence, surveillance, and reconnaissance) missions.
- Therefore, increasing advancements associated with fixed wing aircraft are driving the aircraft heavy maintenance visits market trends.
Rotary wing segment is anticipated to register a substantial CAGR growth during the forecast period.
- Rotary wing aircraft is a type of aircraft that is completely or partly sustained in the air by lifting rotors revolving around a vertical axis.
- Rotary wing aircraft typically include aircraft which consist of rotors that provide lift throughout the entire flight, such as helicopters, gyrodynes, and autogyros.
- Additionally, the primary benefits of rotary wing aircraft includes its ability to fly vertically, hover over a fixed position at a given height, and take off and land in a very small space.
- For instance, in December 2021, the French Armament General Directorate collaborated with Airbus for the procurement and development of military helicopters. The contract includes the development of 169 military helicopters specifically optimized for deployment in the French armed forces.
- Hence, the increasing development of rotary wing aircraft is anticipated to boost the market during the forecast period.
By Service Provider:
Based on component, the market is segmented into MRO service providers, original equipment manufacturers (OEMs), and airlines.
Trends in the service provider:
- Increasing utilization of OEM maintenance services due to high quality assurance, warranty protection, and improved regulatory compliance.
- There is a rising trend towards adoption of maintenance services from MRO service providers due to cost efficiency, quicker turnaround times, and increased flexibility.
The MRO service providers segment accounted for the largest revenue in the overall market in 2024, and it is anticipated to register a significant CAGR growth during the forecast period.
- MRO service providers refer to third-party companies that specialize in offering a range of maintenance services for aircraft, outside of the manufacturer's authorized service centers or the airlines' internal maintenance operations.
- MRO service providers usually offer a range of heavy maintenance services including comprehensive overhaul and refurbishment of aircraft airframes, engines, systems, and components, including structural repairs and replacements.
- MRO service providers often serve various types of aircraft, including commercial jets, cargo planes, helicopters, and general aviation aircraft among others.
- Moreover, MRO service providers often provide competitive pricing compared to OEM service centers along with offering more flexible scheduling and tailored services to meet specific customer needs, which makes it easier for operators to manage their maintenance timeline.
- For instance, AAR Corporation, ST Engineering, and Ascent Aviation Services Corporation are few of the independent MRO service providers that offers heavy maintenance checks and services on a broad range of aircraft.
- According to the aircraft heavy maintenance visits market analysis, the prevalence of substantial number of independent MRO service providers are driving the aircraft heavy maintenance visits market growth.
By End-User:
Based on the end-use, the market is segmented into commercial, military & defense, and others.
Trends in the End-Use:
- Factors including rising air travel trend, growing commercial flight activities, and increasing production of commercial aircrafts are key factors fueling the commercial segment.
- Rising technological advancements in air defense systems, increasing government investments in airborne defense platform, and growing need for advanced military aircraft for enhancement of aerial defense capabilities are primary trends driving the military & defense segment.
Commercial segment accounted for the largest revenue share in the total market share in 2024.
- This dominance is attributed to the rising adoption of aircraft heavy maintenance visits by commercial airline companies to ensure the reliability, safety, and compliance of commercial aircraft operations.
- Moreover, the rise in air travel activities is increasing the need for periodic and comprehensive maintenance services, driven by increased regulatory scrutiny, commercial fleet expansion, aging aircraft, and safety concerns.
- For instance, Airbus delivered 14,950 commercial aircrafts as of September 2023, which includes 11,370 single-aisle aircrafts and 3,580 wide body aircrafts.
- According to the analysis, the rising commercial aircraft fleet is driving the aircraft heavy maintenance visits market size.
Military & defense segment is anticipated to register a significant CAGR during the forecast period.
- In military and defense sector, aircraft heavy maintenance visits play an essential role for ensuring operational readiness, longevity, and compliance of military aircraft.
- Moreover, regular heavy maintenance visits ensure that military aircraft are in optimum condition and ready for deployment. This is vital for maintaining combat readiness and supporting various military operations, ranging from combat missions to humanitarian assistance.
- For instance, in 2023, Shaanxi Aircraft Corporation introduced its new and enhanced special mission aircraft that is optimized for airborne early warning and control operation.
- Therefore, the increasing deployment of military aircraft is expected to drive the demand for aircraft heavy maintenance visits to ensure operational readiness, longevity, and compliance of military aircraft, in turn propelling the market during the forecast period.
Regional Analysis:
The regions covered are North America, Europe, Asia Pacific, the Middle East and Africa, and Latin America.
Asia Pacific region was valued at USD 1,030.42 Million in 2024. Moreover, it is projected to grow by USD 1,061.52 Million in 2025 and reach over USD 1,467.02 Million by 2032. Out of this, China accounted for the maximum revenue share of 34.5%. As per the aircraft heavy maintenance visits market analysis, the adoption of aircraft maintenance visits in the Asia-Pacific region is primarily driven by the increasing production from aerospace & defense sector and rising commercial aircraft fleet among others. Additionally, the rising expenditure on aircraft MRO (maintenance, repair, and operation) activities is further accelerating the aircraft heavy maintenance visits market expansion.
- For instance, according to the International Air Transport Association, the total spending on commercial aircraft MRO activities in Asia-Pacific region was valued at approximately USD 19 billion in 2023, and it is projected to reach up to USD 27 billion by 2033. The above factors are driving the market in the Asia-Pacific region.
North America is estimated to reach over USD 1,951.89 Million by 2032 from a value of USD 1,411.01 Million in 2024 and is projected to grow by USD 1,450.07 Million in 2025. In North America, the growth of aircraft heavy maintenance visits industry is driven by the growing commercial aviation and defense sectors. Similarly, the rising development of commercial aircraft fleet and increasing need for safe and reliable aircraft for commercial operations are contributing to the aircraft heavy maintenance visits market demand.
- For instance, Boeing, a U.S-based aerospace company, delivered approximately 136 commercial aircraft during the second quarter of 2023, depicting an increase of 4.6% in comparison to 130 commercial aircraft deliverables during the first quarter of 2023. The rising commercial aircraft deliverables is projected to drive the aircraft heavy maintenance visits market trends in North America during the forecast period.
The regional analysis depicts that rising production of military and commercial aircrafts along with increasing need for aircraft inspection, maintenance, and repair services are driving the aircraft heavy maintenance visits market demand in Europe. Furthermore, as per the market analysis, the market demand in Latin America, Middle East, and African regions is expected to grow at a considerable rate due to factors such as growing aerospace & defense industry and increasing investments in aircraft MRO activities among others.
Top Key Players and Market Share Insights:
The global aircraft heavy maintenance visits market is highly competitive with major players providing services to the national and international markets. Key players are adopting several strategies in research and development (R&D), product innovation, and end-user launches to hold a strong position in the aircraft heavy maintenance visits market. Key players in the aircraft heavy maintenance visits industry include-
- Lufthansa Technik AG (Germany)
- TU Aero Engines AG (Germany)
- ST Engineering (Singapore)
- Hong Kong Aircraft Engineering Company Limited (Hong Kong)
- Honeywell International Inc. (U.S.)
- Ascent Aviation Services Corporation (U.S.)
- Boeing (U.S.)
- AIRBUS (France)
- Delta TechOPs (U.S.)
- AAR Corporation (U.S.)
Recent Industry Developments:
Partnerships & Collaborations:
- In September 2024, Elbe Flugzeugwerke GmbH, a joint venture of ST Engineering and Airbus, signed a contract with Global Airlines to conduct airframe heavy maintenance services for facilitating its entry into commercial service of the airline’s first Airbus A380 aircraft.
- In February 2024, Ryanair (European airline company) extended their maintenance agreement with Joramco, a Jordan-based MRO service provider. The partnership enables Joramco to conduct heavy maintenance of Ryanair’s aircraft for the subsequent 10 years at their facility in Jordan.
- In November 2023, Airbus announced partnership with Hindustan Aeronautics Limited to support its entry into servicing of commercial aircraft while strengthening the aircraft MRO (maintenance, repair and overhaul) sector in India.
- In May 2022, Boeing and Air Works conducted heavy maintenance checks on anti-submarine warfare aircraft and P-8I long-range maritime patrol that are operated by the Indian Navy at Air Works, Hosur, India.
Aircraft Heavy Maintenance Visits Market Report Insights :
| Report Attributes | Report Details |
| Study Timeline | 2019-2032 |
| Market Size in 2032 | USD 5,644.56 Million |
| CAGR (2025-2032) | 4.4% |
| By Service Type |
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| By Aircraft Type |
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| By Service Provider |
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| By End-Use |
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| By Region |
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| Key Players |
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| North America | U.S. Canada Mexico |
| Europe | U.K. Germany France Spain Italy Russia Benelux Rest of Europe |
| APAC | China South Korea Japan India Australia ASEAN Rest of Asia-Pacific |
| Middle East and Africa | GCC Turkey South Africa Rest of MEA |
| LATAM | Brazil Argentina Chile Rest of LATAM |
| Report Coverage |
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Key Questions Answered in the Report
How big is the aircraft heavy maintenance visits market? +
The aircraft heavy maintenance visits market was valued at USD 4,079.44 Million in 2024 and is projected to grow to USD 5,644.56 Million by 2032.
Which is the fastest-growing region in the aircraft heavy maintenance visits market? +
Asia-Pacific is the region experiencing the most rapid growth in the aircraft heavy maintenance visits market.
What specific segmentation details are covered in the aircraft heavy maintenance visits report? +
The aircraft heavy maintenance visits report includes specific segmentation details for service type, aircraft type, service provider, end-use, and region.
Who are the major players in the aircraft heavy maintenance visits market? +
The key participants in the aircraft heavy maintenance visits market are Lufthansa Technik AG (Germany), TU Aero Engines AG (Germany), Ascent Aviation Services Corporation (U.S.), Boeing (U.S.), AIRBUS (France), Delta TechOPs (U.S.), AAR Corporation (U.S.), ST Engineering (Singapore), Hong Kong Aircraft Engineering Company Limited (Hong Kong), and Honeywell International Inc. (U.S.).
