Digital MRO Market Size, Share & Trends Analysis Report By Technology (Predictive Maintenance, AR/VR, 3D Printing, Blockchain, Internet of Things (IoT), Artificial Intelligence, Big Data Analytics, Robotics, Digital Twin), By Applications (Predictive Analysis, Inspection, Performance Monitoring, Part Replacement, Mobility and Functionality), By End-User (Airlines, MRO Providers, OEMs) and By Region(North America, Europe, APAC, Middle East and Africa, LATAM) Forecasts, 2024-2032

Market Overview

The global digital MRO market size was valued at USD 1,394.43 million in 2023. It is expected to reach USD 3,942.08 million in 2032, growing at a CAGR of 12.24% over the forecast period (2024-32). The aerospace industry is increasingly adopting digital technologies to enhance operational efficiency, reduce downtime, and improve safety. Digital MRO solutions leverage technologies such as IoT (Internet of Things), big data analytics, AI (Artificial Intelligence), machine learning, and blockchain to streamline maintenance processes, predict failures and optimize asset management.

Maintenance, repair, and overhaul (MRO) operations are going through a rapid transformation as service providers increasingly adopt digital technologies. Digital MRO is the practice of doing MRO operations using digital technologies, including the Internet of Things (IoT), blockchain, artificial intelligence (AI), robotics, augmented reality (AR), virtual reality (VR), digital twins, and 3D printing. These technologies increase the efficiency of operations and reduce turnaround time. The difference between MRO and MRP is that MRP (Material requirements planning) refers to a computerized inventory system that helps businesses accurately predict the amounts of raw materials needed per unit of time to maximize productivity while remaining cost-effective. In contrast, MRO refers to the physical items used by manufacturers to create their final products.

Market Dynamics

Global digital mro market drivers

Adoption of advanced technologies by mro service providers

Recently, aircraft MRO providers have been using new technologies such as 3D printing to manufacture complex aircraft parts. Companies use 3D printed parts as they are economical and allow quick design and rapid changes of internal features in engines and components, which is impossible in conventional manufacturing methods. This has helped reduce the size and weight of the entire aircraft while increasing customization and overall maintenance efficiency. Thus, 3D-printed aircraft parts would reduce the overall MRO costs and act as substitutes for conventionally manufactured aircraft parts.

Likewise, integrating the Internet of Things (IoT) with digital MRO services would assist third-party MRO service providers in connecting better with their customers and serving them using business intelligence and data analytics. Many companies, such as Honeywell International Inc., are looking to integrate IoT with their MRO services to provide practical, convenient, and smart solutions. As a result, MRO service providers have much to gain from implementing such technologies, which is anticipated to fuel the worldwide digital MRO market's expansion throughout the forecast year.

Growth in outsourcing mro services

There has been an increase in MRO service providers outsourcing MRO activities to small companies specialized in an engine, airframe, line, or component maintenance. Outsourcing aircraft MRO to third-party companies is a significant driver for the growth of the global digital MRO market during the forecast period. There has been an increase in MRO outsourcing due to the growing awareness of the benefits, such as low labor rates and the availability of adequate spare parts. For example, engine maintenance involves high costs due to the need for specialized infrastructure and a skilled workforce. Outsourcing inventory and infrastructure required to carry out maintenance reduces the overall cost for the MRO service providers. MRO digital signature services include efficiently managing this aircraft MRO outsourcing and reducing the overall maintenance cost, thereby driving the market growth.

Global digital mro market restraint

Inconsistency and replacement of traditional data connection

Data management and collection is a significant factor restraining the growth of the global digital MRO market. MRO digital transformation transmits large volumes of digital data to servers used at various application levels. The increasing adoption of IoT in aviation and technological advances in the industry necessitates ample storage to manage the data transmitted from multiple processes. Moreover, issues related to inconsistency due to using conventional systems in aircraft create connectivity issues. Furthermore, problems with analyzing and storing this data can reduce the efficiency of operations, which will likely hinder the growth of the global digital MRO market during the forecast period.

Global digital mro market opportunities

Availability of aftermarket parts on e-commerce platforms

Distribution networks play a vital role in the availability of components at a location. Introducing e-commerce platforms in distribution networks improves the overall efficiency of aftermarket parts providers. They enable suppliers to forecast the number of orders and manage resources and time accordingly. Moreover, suppliers can make them available in less time from their inventories and other resources in the case of unavailable parts. For customers, these platforms are beneficial as they can easily select the required details and place an order with reduced turnaround time and cost comparison. Thus, e-commerce platforms could play a significant role in the supply chain of digital MRO, which presents a lucrative opportunity for the players operating in the global digital MRO market during the forecast period.

Regional Analysis

By region, the global digital MRO market is divided into North America, Europe, Asia-Pacific, Latin America, and the Middle East and Africa. 

North america dominates the global market

North America is the most significant shareholder in the global digital MRO market and is anticipated to grow at a CAGR of 13.13% during the forecast period. There are numerous primary and medium-sized MROs and airlines in this area. The need for digital MRO in North America is also anticipated to rise due to an increase in MRO service providers and a growing requirement for digital MRO transformation. Furthermore, the regional market growth is driven by increasing aircraft from players in the US and Canada. It is expected that approximately 10,000 aircraft will be in service in the region by 2035, which is expected to create additional opportunities for the players operating in the North American digital MRO market. Additionally, the market in the US is expanding due to the presence of well-known players like Boeing, IBM Corporation, Oracle Corporation, TRAXXALL, Honeywell International Inc., General Electric (GE), and CAPGEMINI. 

Asia-Pacific is expected to grow at a CAGR of 12.38% over the forecast period. Asia-Pacific is gaining prominence in the global aviation industry and is projected to become the world's leading market for air travel. Moreover, the presence of key players such as HCL Technologies and Ramco Systems Limited and increasing inorganic growth by these players are propelling the regional market's growth. Furthermore, based on the statistics provided by the IATA, China is set to overtake the US and become the leading air passenger traffic market. According to IATA, by 2035, air passenger traffic in India would surpass the UK to be the third-highest in the world, with the addition of over 322 million passengers, reaching a total of 442 million. Additionally, the opening up of new international routes by airlines based in the country and the modernization of airline services are set to impact the Asia-Pacific digital MRO market's growth positively. The growing passenger traffic in these countries and the rising number of short-haul flights are likely to propel the demand for digital MRO in this region.

In Europe, the rapid advancements in MROs and the increasing adoption of digital predictive analysis solutions by regional airlines propel the digital MRO market's growth. Furthermore, initiatives are being taken by the provincial government agencies to aid research activities and rise in collaborative strategies in the region, propelling regional growth. For instance, in March 2019, DLR, a German aerospace research center, inaugurated a research center at the ZAL aerospace research facility. This facility is dedicated to developing future aircraft maintenance processes and received a grant of USD 1.1 million from the regional government. 

Moreover, increases in aircraft in the region created a massive demand for digital MRO. For instance, in 2017, there were approximately 5,000 aircraft in the region; the number is expected to reach over 8,000 fleets by 2035. Furthermore, well-known businesses like SAP SE (SAP) and IFS AB are anticipated to fuel market expansion in the area. Moreover, developing new airports with advanced MRO facilities is expected to drive regional market growth during the study period.

The growing number of symposiums and conferences in the Middle East and Africa region is anticipated to increase business opportunities. Large regional corporations, such as Etihad Airways Engineering, Lufthansa Technik Middle East, and Execujet MRO Services, are expected to increase the need for digital MRO services. The demand for new aircraft is anticipated to increase due to increased air traffic, which would likely support the digital MRO business. In addition, leading regional airlines have increased their investment in new technology. As per the Aviation Week 2020 commercial fleet and MRO forecast, fleets in the Middle East are expected to double nearly. Increasing passengers and availability of MRO service providers have made a considerable investment in technologies such as predictive analytics, predictive maintenance, and artificial intelligence upgrades. Hence, the digital MRO market in the Middle East and Africa is expected to grow during the forecast period. 

Segmental Analysis

The global digital MRO market is segmented into technology, application, and end-user.

Based on technology

The global digital MRO market is divided into predictive maintenance, AR/VR, 3D printing, blockchain, Internet of Things (IoT), artificial intelligence, big data analytics, robotics, and digital twin. 

The predictive maintenance segment is the highest contributor to the market and is expected to grow at a CAGR of 11.56% during the forecast period. Predictive maintenance is used in aircraft maintenance and engineering first to determine when a component failure might happen and then stop the loss from happening by doing maintenance. The rising use of big data analytics tools to make maintenance processes more efficient and significantly reduce operating costs drives this segment's growth. According to the MRO survey 2017, "When Growth Outpaces Capacity," 77% of respondents want to implement predictive analytics in the upcoming years. In October 2019, Airbus (Leiden, Netherlands) and Delta Air Lines (Georgia, US) formed a digital alliance to develop new predictive maintenance and health monitoring solutions for airline customers worldwide. Therefore, the rising number of collaborative development activities and the increasing number of airlines expected to adopt predictive maintenance is anticipated to drive the growth of this segment.

IoT's continued progression and implementation are transforming the aircraft MRO industry, providing access to once-limited data information and innovative solutions, and enabling insightful maintenance data that decrease operational costs, unlock new revenue streams, and improve aircraft on-the-ground time. The data generated from the aviation industry create operational dashboards that allow airlines to maximize fuel efficiency through optimized trajectory and navigation. Even with crew management, catering, load balancing, and onboard provisioning, connected devices can bring data closer to generating value for passengers.

Based on application

The global digital MRO market is divided into predictive analysis, inspection, performance monitoring, part replacement, and mobility and functionality. 

The predictive analysis segment owns the highest market share and is expected to grow at a CAGR of 11.55% during the forecast period. The aviation MRO industry is experiencing the shrinking of traditional IT. Many players move from custom legacy software to a new generation of MRO applications, which help move to digital. Using big data helps create dashboards to analyze inventory and maintenance needs. For instance, HCL (India) has created an application built on the SAP Cloud platform that supports the maintenance of engines by integrating IoT devices to address specific technical problems related to engine maintenance and repair operations. Its aircraft predictive analytics measures key parameters such as temperature, pressure, physical fan speed, and bypass ratio to predict the remaining usable life of an aircraft engine and therefore plan maintenance accordingly. In addition, the availability of offerings such as Skywise Health Monitoring by Airbus, Prognos by Air France Industries, KLM Engineering & Maintenance, and FlightSense and Ascentia by Collins Aerospace for predictive analysis is anticipated to drive the growth of this segment.

Aircraft companies and operators are pushing for faster troubleshooting, automated aircraft inspection to reduce downtime, better task planning, and optimized parts management. British companies EasyJet and Thomas Cook Airlines have experimented with an autonomous drone, developed by MRO Drone, to inspect a complete narrow-body exterior in 30 minutes and a widebody in one hour. The availability of rental equipment from companies for MRO is advancing the growth of this segment. 

Based on end-user

The global digital MRO market is divided into airlines, MRO providers, and OEMs. 

The airline segment is the highest contributor to the market and is anticipated to grow at a CAGR of 11.45% over the forecast period. Repairing, servicing, or inspecting an aircraft or an aircraft component is referred to as maintenance, repair, and overhaul (MRO) in the aviation industry. It generally encompasses all maintenance procedures to maintain all aircraft in compliance with international aviation regulations for safety and airworthiness. Additionally, the International Civil Aviation Organization reports that during the past 20 years, the aviation industry has experienced dramatic expansion, with passenger numbers increasing from 1.4 billion in 1998 to 3.9 billion in 2017. Further, India had 103 operating airports as of March 2019; India wants to have between 190 and 200 operational airports by 2040. The growing number of air passengers and an increasing number of airports are anticipated to grow this segment.

The demand for air travel and growing aircraft fleet have propelled the commercial airline maintenance, repair, and overhaul (MRO) market into steady growth. In 2018, the two aircraft manufacturers, Airbus and Boeing, indicated they expect to exponentially increase their MRO business over the next several years. The growth in the number of strategic decisions by key companies is anticipated to grow the segmental growth.

Recent Developments

• February 2024 - Pratt & Whitney, an RTX (NYSE: RTX) company, announced that the inauguration of its Singapore Technology Accelerator (STA). This has resulted in a major advancement in maintenance, repair, and overhaul (MRO) performance.
• May 2024 - An exciting announcement was made by Asia Digital Engineering (ADE), Capital A's Maintenance, Repair, and Operations (MRO) division, regarding ADE Cambodia Co Ltd (ADE Cambodia), its joint venture with Sivilai Asia Co Ltd, having received the Approved Maintenance Organization (AMO) certification from the Cambodia State Secretariat of Civil Aviation (SSCA).