Supply chain challenges are projected to cost the world's airlines more than $11 billion in 2025, according to analysis from the International Air Transport Association. About $3.1 billion of that total comes from extra maintenance spending on aging aircraft, as carriers keep older jets in service longer while waiting on delayed deliveries of new airplanes.

The maintenance bill itself keeps climbing. Global MRO spending reached approximately $104 billion in 2024, an 11.7 percent increase over 2019 levels, based on IATA's Maintenance Cost data eXchange, which collects cost data from more than 50 airlines representing about a quarter of the world's fleet. Maintenance now accounts for 11.5 percent of total airline operating expenses, up from 10 percent in 2019, a shift that reflects both higher labor and parts costs and the heavier upkeep older fleets demand.

The pressure is expected to persist. Industry forecasts tied to the same data set point to global maintenance spending of approximately $124 billion by 2034, about a third higher than 2019. For US carriers and repair stations, the figures translate into sustained demand for engine shop visits, component repairs, and heavy checks, along with continued competition for scarce parts and skilled technicians.

Source: IATA - https://www.iata.org/en/pressroom/2025-releases/2025-10-13-01/