Why Airlines Are Scrambling To Make Engines Last Longer
Air travel is on the rise again but airlines and maintenance facilities are facing increasing pressure to keep fleets in prime working order. According to a recent CNBC article, the repair and overhaul of aircraft engines has swelled from a $31 billion business before the pandemic to $58 billion in 2024.
Alongside the rebound in passenger traffic since the pandemic, demand for engines and spare parts has soared, while global supply chain issues and labour constraints continue to limit repair shop throughput. Airlines need to turn planes around faster, often paying a premium to get critical engine work done and avoid the delays and lost revenue that come with grounded aircraft.
Under the circumstances, MRO providers are scrutinising every aspect of their processes to find time and cost efficiencies. Even seemingly straightforward procedures like removing and replacing worn parts can become prolonged if components are fused, corroded, or otherwise stuck. Delays of just a few hours can balloon into major disruptions when multiplied across large fleets, strict repair timelines, and complex global logistics. These slowdowns carry a considerable financial and environmental toll.
The landscape for MROs is challenging. Older jets are remaining in service for longer and demanding more frequent maintenance, but access to crucial spare parts is limited. Meanwhile, supply chain bottlenecks drive up costs, and engine repair shops struggle with staff shortages. The renewed demand for air travel is encouraging for the sector, but engine repair processes remain vulnerable to external pressures. These factors underscore the importance of optimising maintenance workflows.
Scintam’s innovative FastEDR system uses electrical discharge machining (EDM) to remove seized or corroded fasteners quickly and safely, a vital step in nearly every engine overhaul.
Rather than manually drilling or grinding, FastEDR dissolves seized fasteners, minimising damage to high-value parts, eliminating heat-related risks, and reducing labor-intensive work. Compact and portable, the system can access tight spaces, work with high-strength metals used in modern engines, and dramatically shorten maintenance timelines. By lowering scrap rates, where a single damaged HPC drum can cost airlines $250,000, FastEDR substantially derisks engine MRO processes.
The demand for reliable, efficient engine maintenance is unlikely to subside and could even intensify in the coming years. With 2024 engine repair spending 87% higher than pre-pandemic levels, airlines and MRO providers are facing the need to streamline operations. Solutions that help reduce turnaround times and cut operating costs could prove to be game-changers.
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