Maintenance, Repair, and Operations: The 2025 Industry Update

1. Resilient Growth Amid Challenges

The MRO sector is showing strong momentum—global spending rebounded in 2024, reaching over $114 billion, a 7.2% increase above pre-pandemic levels. Despite slower growth trends, the industry is projected to maintain a steady annual growth of approximately 2.7%–2.8% through 2035.

2. Fleet Expansion Driving Demand

Commercial aircraft fleets continue to expand rapidly. Oliver Wyman forecasts around 2.8% annual growth, with the number of commercial aircraft rising from just over 29,000 in 2025 to 38,300 by 2035 STS Aviation Group. Aviation Week also suggests MRO demand could exceed $282 billion in 2025, driven by both engine, airframe, and component workloads.

3. Operational Constraints: Engines & Supply Chains

Engine maintenance bottlenecks are a growing issue: repair wait times have jumped—up 150% for modern engines, and 35% for older models. Meanwhile, global supply chain fragility continues to delay access to critical parts. Industry leaders like GE Aerospace are investing over $1 billion in capacity upgrades to mitigate disruptions.

4. Innovation: AI, Additive Manufacturing & Digital Platforms

AI and predictive maintenance are transforming the sector. According to Aviation Week, more than 81% of firms are exploring AI/ML solutions to optimize inventory, capacity, and maintenance forecasts Source One Spares Blog . M&A activity is also on the rise as firms seek to integrate vertically—expanding into specialized parts repair, data platforms, and OEM partnerships. Additive manufacturing is accelerating engine part turnaround. RTX’s Pratt & Whitney has unveiled a 3D repair process for GTF engine components that cuts repair time by over 60%, lowers tooling costs, and reduces supply chain dependence—potentially recovering $100 million in parts over five years.

5. Regional Highlights & Facility Upgrades

India's MRO footprint is expanding. Air India Engineering Services at Thiruvananthapuram Airport earned EASA Part-145 certification, becoming South India’s first and India's second such facility. They’re constructing a wide-body hangar to serve Europe, Gulf, and Southeast Asian markets. Malaysia's ADE is capitalizing on new aircraft shortages to grow rapidly. Fully booked through 2025, ADE has doubled its revenue and is developing predictive maintenance software and an online parts marketplace. Thailand, Andhra Pradesh, and Queensland are positioning themselves strategically as MRO hubs—thanks to MRO-friendly policies and investment in talent and infrastructure.

6. Manufacturing & Industrial MRO: Smart and Sustainable

Outside aviation, industrial MRO is also embracing digital transformation. Global MRO market size estimates vary: IMARC projects a $700 billion market in 2025, growing to $842 billion by 2033 at a 2.33% CAGR Mordor Intelligence. Mordor Intelligence pegs it at $440.8 billion in 2025, with a forecast of $493.4 billion by 2030 at a 2.3% CAGR. In the U.S., the MRO sector is estimated at $93.2 billion in 2025, with moderate growth expected. Industrial maintenance is leaning on platforms like MaintainX, which offer real-time tracking, AI-based preventative maintenance, and streamlined operations management.