North America Aircraft Parts Market Report

North America Aircraft Parts Market Size

The North American aircraft parts market was valued at USD 9.46 billion in 2024 and is anticipated to reach USD 10.04 billion in 2025 to USD 16.52 billion by 2033, growing at a CAGR of 6.13% during the forecast period from 2025 to 2033.

The aircraft parts include original equipment manufacturer (OEM) components as well as aftermarket replacements, covering systems such as propulsion, avionics, landing gear, flight control surfaces, and cabin interiors. The region’s aerospace ecosystem is anchored by the United States, which hosts the world’s largest air transportation network and a deeply integrated defense-industrial base. As per the Federal Aviation Administration, over 21,000 commercial aircraft are currently registered in the U.S., forming the backbone of a maintenance-intensive fleet requiring continuous parts replenishment.

MARKET DRIVERS

Expansion of Commercial Air Travel and Fleet Modernization Programs

The sustained expansion of commercial air travel and the associated fleet modernization initiatives are driving the growth of the North American aircraft parts market. According to the International Air Transport Association, North American airlines carried over 940 million passengers in 2023, a 17% increase from 2022 and 5% above 2019 levels. This surge in traffic necessitates not only new aircraft deliveries but also extensive retrofitting and component upgrades on existing fleets to meet evolving safety, efficiency, and environmental standards. Boeing’s 2023 Commercial Market Outlook projects that North American carriers will require more than 9,300 new aircraft over the next 20 years, each demanding thousands of precision-engineered parts. The Federal Aviation Administration mandates that over 300 components per aircraft undergo scheduled replacement or overhaul, creating a steady aftermarket demand. Airlines like Delta and United have launched fleet-wide cabin modernization programs, which are replacing seats, galleys, and in-flight entertainment systems, further stimulating parts procurement.

Increased Defense Spending and Military Aircraft Sustainment

The escalation in U.S. defense expenditures and the strategic focus on military aircraft sustainment are additionally prompting the growth of the North American aircraft parts market. As per the U.S. Department of Defense’s 2024 budget request, over $276 billion was allocated to procurement and sustainment, with a significant portion directed toward maintaining and upgrading legacy platforms such as the F-15EX, B-52 Stratofortress, and C-130J Super Hercules. Many of these aircraft, some over 50 years old, remain in continuous supply of certified spare parts to ensure operational readiness. Additionally, the F-35 Joint Program Office has established a global logistics network that sources more than 80% of its replacement parts from North American suppliers, which is reinforcing regional manufacturing dominance. Canada’s commitment to NORAD modernization and its acquisition of F-35s for the Royal Canadian Air Force further amplifies demand.

MARKET RESTRAINTS

Supply Chain Disruptions and Raw Material Shortages

The persistent vulnerability of the aerospace supply chain to disruptions and raw material shortages in high-performance alloys and specialty composites is restricting the growth of the North American aircraft parts market. The production of turbine blades, structural frames, and landing gear relies heavily on materials such as titanium, nickel-based superalloys, and carbon fiber, which are subject to geopolitical volatility and limited sourcing. As per the U.S. Geological Survey, the United States imports over 90% of its titanium sponge from Japan and Kazakhstan by leaving manufacturers exposed to export restrictions and shipping delays. As per the Aerospace Industries Association in 2023, 42% of Tier-2 and Tier-3 aerospace suppliers experienced at least one material delay exceeding eight weeks in the prior year. The semiconductor shortage, while easing, still affects avionics production, with Honeywell citing a 30% reduction in production capacity for flight management systems in early 2023. These disruptions extend lead times, increase inventory costs, and delay aircraft maintenance cycles.

Stringent Regulatory Compliance and Certification Delays

The rigorous regulatory environment governing component certification and airworthiness compliance is significantly hindering the growth of the North American aircraft parts market. Every aircraft part, whether OEM or aftermarket, must meet exacting standards set by the Federal Aviation Administration (FAA) or Transport Canada, involving extensive documentation, testing, and traceability protocols. According to the FAA’s Office of Aerospace Certification, the average time to approve a new aircraft component design has increased from 14 to 22 months between 2018 and 2023, due to heightened scrutiny following safety incidents. Parts requiring Supplemental Type Certificates (STCs) often face multi-year approval timelines, discouraging smaller manufacturers from entering the market.

MARKET OPPORTUNITIES

Adoption of Additive Manufacturing for Complex Aircraft Components

The widespread adoption of additive manufacturing (AM), commonly known as 3D printing, for the production of complex and lightweight components is expected to enhance the growth of the North American aircraft parts market in the coming years. This technology enables the creation of intricate geometries such as fuel nozzles, turbine blades, and ducting systems that are unattainable through traditional machining, while reducing material waste and assembly time. GE Aviation has already integrated 3D-printed fuel nozzles into its LEAP engine fleet, with over 100,000 parts produced by 2023, demonstrating scalability and reliability. Additionally, the Federal Aviation Administration has certified more than 500 3D-printed parts for flight use since 2020, signaling regulatory confidence. In Canada, the National Research Council’s Additive Manufacturing Program supports aerospace firms in qualifying AM processes for certification.

Growth in Aircraft Modifications and Retrofitting for Sustainability

The increasing emphasis on aviation sustainability, with the expansion of aircraft modification and retrofitting programs aimed at improving fuel efficiency and reducing emissions, is creating opportunities for the expansion of the North American aircraft parts market. Airlines and operators are investing heavily in cabin upgrades, aerodynamic enhancements, and engine performance improvements to meet environmental targets and extend the service life of existing fleets. According to the International Civil Aviation Organization, North American carriers are required to achieve a 2% annual improvement in fuel efficiency through 2030 under the Carbon Offsetting and Reduction Scheme for International Aviation (CORSIA).

MARKET CHALLENGES

Workforce Shortages in Skilled Aerospace Manufacturing and MRO Technicians

A growing challenge in the North American aircraft parts market is the acute shortage of skilled labor in aerospace manufacturing, engineering, and maintenance, repair, and overhaul (MRO) operations. As per the Aerospace Industries Association, the U.S. aerospace sector will need to fill over 190,000 skilled positions by 2030 due to retirements and expansion, but current training pipelines are insufficient to meet demand. Community colleges and technical schools produce only about 12,000 aerospace graduates annually, creating a shortfall of nearly 80,000 workers over the decade. The Bureau of Labor Statistics reports that the median age of aircraft mechanics is 47, with over 35% expected to retire by 2030. In Canada, the Aerospace Skills Canada initiative estimates a deficit of 15,000 workers by 2026, particularly in Quebec and Manitoba’s manufacturing hubs. This shortage delays production schedules, increases labor costs, and compromises quality control.

Rising Cybersecurity Threats in Digitalized Aircraft Systems and Supply Chains

The increasing digitization of aircraft systems and supply chain operations is additionally challenging the growth of the North American aircraft parts market. Modern aircraft rely on interconnected avionics, fly-by-wire systems, and software-driven maintenance platforms, all of which are vulnerable to cyber intrusions. According to the U.S. Government Accountability Office, the number of reported cyber incidents in the aerospace sector increased by 57% between 2020 and 2023, with attacks aimed at stealing intellectual property and disrupting production. In 2022, a ransomware attack on a Tier-1 supplier compromised design schematics for engine components, delaying deliveries to multiple OEMs. The Department of Homeland Security’s Cybersecurity and Infrastructure Security Agency has identified over 200 vulnerabilities in common aircraft maintenance software platforms used across North American MRO facilities. Additionally, the integration of digital twins and cloud-based inventory systems exposes parts traceability data to potential tampering, risking counterfeit component infiltration.

REPORT COVERAGE

SEGMENT ANALYSIS

By Parts Insights

The MRO (Maintenance, Repair, and Overhaul) Parts segment accounted in holding 58.3% of the North America aircraft parts market share in 2024, wth the presence of vast and aging commercial and military aircraft fleets, which necessitate continuous inspection, component replacement, and airworthiness compliance. The Federal Aviation Administration mandates that every commercial aircraft undergo routine checks ranging from A-checks every 500 flight hours to D-checks every six years, each requiring the replacement or overhaul of hundreds of components. As per the Bureau of Transportation Statistics, the average age of the U.S. narrowbody fleet exceeds 11.4 years, with over 3,200 Boeing 737s and Airbus A320s in service past their 15-year threshold, significantly increasing their MRO intensity.

The Rotatable Scrap Replacement Parts segment is expected to grow with a CAGR of 9.8% from 2025 to 2033, owing to the increasing retirement of older aircraft and the need to sustain legacy fleets through component reuse and overhaul. According to the U.S. Government Accountability Office, over 1,400 commercial aircraft were permanently retired between 2020 and 2023, yet 60% of their high-value components were salvaged for reuse. Airlines are increasingly adopting circular economy models, where retired aircraft are disassembled, and functional parts are refurbished for resale.

By Application Insights

The commercial aviation segment was the largest by occupying a prominent share of the North American aircraft parts market in 2024. The growth of the segment is driven by the region’s expansive commercial airline network, high passenger traffic, and extensive fleet size. The United States operates the world’s largest commercial aviation system, with over 5,000 aircraft in service across major carriers such as American, United, Delta, and Southwest. According to the Bureau of Transportation Statistics, U.S. airlines transported more than 940 million passengers in 2023, requiring continuous maintenance and parts replenishment to sustain operational reliability. The average daily utilization of narrowbody aircraft exceeds 10.5 hours, intensifying wear on engines, landing gear, and avionics. Additionally, the widespread adoption of long-haul, widebody aircraft like the Boeing 787 and Airbus A350 has increased demand for advanced composite parts and fuel-efficient systems. The Federal Aviation Administration conducts over 200,000 aircraft inspections annually, many of which result in part replacements.

The military aviation segment is expected to register a CAGR of 10.3% from 2025 to 2033, owing to the sustained defense spending, fleet modernization, and the extension of service life for legacy platforms. The U.S. Department of Defense’s 2024 budget allocates $178 billion for aircraft procurement and sustainment, with a significant portion directed toward parts and upgrades. As per the Air Force Life Cycle Management Center, over 70% of active U.S. military aircraft are beyond their original design service life, including B-52s, F-15s, and C-130s, all requiring continuous component replacement. The F-35 Joint Program Office has established a global logistics network that sources over 80% of its spare parts from North American suppliers. Additionally, Canada’s commitment to NORAD modernization and its acquisition of 88 F-35s for the Royal Canadian Air Force is driving demand for avionics, engines, and structural components.

COUNTRY LEVEL ANALYSIS

United States

The United States was the top performer of the North American aircraft parts market with 82.3% of the share in 2024. The Federal Aviation Administration oversees more than 21,000 registered aircraft, including over 5,000 commercial jets and 18,000 general aviation aircraft. Boeing, headquartered in Chicago, remains a cornerstone of OEM production, while GE Aviation, Pratt & Whitney, and Honeywell lead in engine and avionics systems. The country is home to over 1,200 FAA-certified MRO facilities, which ensure robust aftermarket support. The Department of Defense’s $842 billion budget for 2024 includes substantial funding for aircraft sustainment, reinforcing military parts demand. Additionally, the U.S. leads in additive manufacturing and digital MRO solutions, with companies like Relativity Space and Stratasys pioneering next-generation production.

Canada

Canada was positioned second with 13.2% of the North American aircraft parts market share in 2024. The growth of the market in Canada is driven by Quebec serving as a major hub for aerostructures, engines, and avionics. Bombardier, Pratt & Whitney Canada, and CAE are key contributors, producing components for global OEMs. Transport Canada maintains rigorous airworthiness standards, ensuring high-quality part certification. The country operates a diverse fleet, including commercial aircraft, military jets, and regional turboprops, all requiring ongoing maintenance. The National Research Council of Canada supports innovation in composite materials and sustainable aviation technologies. Additionally, Canada’s participation in NORAD and NATO drives defense-related parts procurement.

KEY MARKET PLAYERS

AAR (US), Walter Aviation Limited (UK), Eaton (Ireland), Parker Hannifin Corporation (US), Aviall (US), Kellstrom Aerospace (US), General Electric (US), Honeywell International Inc. (US), Meggitt PLC (England), Collins Aerospace (US). are the market players that are dominating the North America aircraft parts market.

Top Players in the Market

Boeing

Boeing stands as the top player of the North American aircraft parts market by leveraging its dual role as an original equipment manufacturer and a comprehensive service provider. Beyond assembling commercial and military aircraft, the company produces a vast array of proprietary components, including fuselage sections, flight control systems, and avionics integration modules. Its Global Services division plays a pivotal role in the aftermarket, offering maintenance solutions, parts distribution, and digital fleet management tools that enhance aircraft reliability and operational efficiency. Boeing’s influence extends globally through its supply chain partnerships, technical support networks, and collaboration with airlines on lifecycle management programs.

General Electric Aviation (GE Aviation)

GE Aviation is a dominant force in the North American aircraft parts market, particularly in propulsion and engine systems. The company designs and manufactures high-thrust turbofan engines, such as the GE9X and LEAP series, which power a significant portion of the global narrowbody and widebody fleets.

Honeywell Aerospace

Honeywell Aerospace is a key contributor to the North American aircraft parts market, specializing in avionics, mechanical systems, and auxiliary power units. The company’s components range from flight management systems and navigation sensors to environmental control units and landing gear actuators that are integrated into both commercial and military platforms worldwide. Honeywell combines deep engineering expertise with digital innovation, offering connected aircraft solutions that enhance situational awareness and operational efficiency. Its service network provides global MRO support, ensuring part reliability and regulatory compliance. The company’s focus on sustainability has led to advancements in lightweight materials and energy-efficient systems.

COMPETITION OVERVIEW

The competitive landscape of the North American craft parts market is defined by a blend of technological, regulatory mastery, and strategic agility among a select group of established aerospace giants. Competition is less about price and more centered on performance, compliance, and lifecycle support, with companies differentiating themselves through innovation in materials, digital integration, and sustainability. OEMs maintain strong influence through proprietary designs and exclusive service rights, while specialized suppliers carve niches in high-precision components such as avionics, actuators, and engine systems. The aftermarket segment fosters intense rivalry between OEMs and independent MRO providers, each vying for service contracts through cost efficiency and technical excellence. Emerging players are gaining ground through additive manufacturing and component modernization, which are challenging traditional production models.

RECENT HAPPENINGS IN THE MARKET

• In February 2023, Boeing launched its Digital Parts Marketplace, an online platform enabling airlines and MRO providers to procure certified spare parts with real-time inventory tracking and blockchain-based traceability. This initiative is anticipated to streamline supply chain operations and enhance transparency across the aftermarket network.
• In July 2023, GE Aviation expanded its additive manufacturing facility in Huntsville, Alabama, to increase production capacity for 3D-printed fuel nozzles and turbine components. This expansion is expected to accelerate part delivery timelines and support next-generation engine programs.
• In October 2023, Honeywell introduced a new suite of connected avionics upgrades for legacy business jets by enabling satellite-based navigation and real-time maintenance alerts. This enhancement is projected to extend the service life of older aircraft and strengthen Honeywell’s foothold in the retrofit market.
• In January 2024, Spirit AeroSystems inaugurated a new composite wing component line in Wichita, Kansas, focusing on next-generation structures for the Boeing 737 MAX and future narrowbody platforms. This development is expected to reinforce its role as a primary structural supplier.
• In May 2024, Collins Aerospace, a Raytheon Technologies company, unveiled an integrated electric taxiing system for commercial aircraft, which is reducing engine wear and ground-level fuel consumption. This innovation is anticipated to drive demand for new mechanical and power distribution components.

MARKET SEGMENTATION

This research report on the North American aircraft market is segmented and sub-segmented into the following categories.

By Parts Type

• MRO Parts
• Rotatable Scrap Replacement Parts
• Consumable
• Expendable

By Application Type

• Commercial
• Military

By Country

• North America
• US
• Canada