Global spending on maintenance, repair, and overhaul (MRO) is expected to increase steadily over the next decade, growing from US$124 billion in 2025 to US$153 billion by 2035, according to Alton Aviation Consultancy newly released 2025–2035 Global MRO Demand Forecast....
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Global spending on maintenance, repair, and overhaul (MRO) is expected to increase steadily over the next decade, growing from US$124 billion in 2025 to US$153 billion by 2035, according to Alton Aviation Consultancy newly released 2025–2035 Global MRO Demand Forecast.
The report forecasts a global compound annual growth rate of 1.9%. North America is expected to see above-average growth at 2.7% per year, driven largely by rising engine-related costs and growing demand in the modifications segment. The Asia-Pacific region is set to retain its position as the largest MRO market, accounting for more than one-third of global spend by 2035.
“Demand for MRO remains robust, despite global supply chain pressures driving up costs for MROs,” said Adam Guthorn, report co-author and managing director in Alton’s New York office. “Airlines are prioritizing capacity growth to meet rising passenger demand, and with fewer retirements, older, more maintenance-intensive aircraft are remaining in service longer. At the same time, the fleet is becoming increasingly reliant on new-generation engines, many of which are experiencing early reliability issues. Combined with OEM production delays and inflation in labor and materials, this is fueling a strong MRO market.”
The report identifies engine maintenance as the dominant category of MRO expenditure, with spending underpinned by persistent durability issues affecting new-generation engines. Cabin modifications are also expected to see rapid growth in the coming decade.
“Engine maintenance continues to dominate MRO spend, accounting for nearly half of all expenditures, driven by new-generation engine durability issues,” said Alan Lim, report co-author and director in Alton’s Singapore office. “Meanwhile, cabin modifications are emerging as one of the fastest-growing segments, with spending set to grow from $4.3 billion in 2025 to $6.6 billion by 2035, as airlines upgrade fleets and enhance passenger experience.”
However, the report also highlights a degree of uncertainty in the near-term outlook, with broader macroeconomic and geopolitical risks that could affect MRO demand.
“While demand remains strong, risks of an economic recession and ongoing geopolitical tensions persist,” Lim added. “An increase in global trade friction led by US tariffs could threaten global economic recovery, impacting aircraft utilization and MRO demand.”
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