A deepening global shortage of maintenance capacity for the world’s most widely used next-generation jet engines is crippling airline operations and risks worsening as aircraft fleets expand, the International Air Transport Association said on Wednesday.
A study released by IATA and consulting firm Emerton found that durability problems, shortages of spare parts and limited access to maintenance capacity have created significant challenges for airlines operating CFM International LEAP engines and Pratt & Whitney’s Geared Turbofan engines, which power most newly delivered single-aisle aircraft.
The industry group warned that maintenance, repair and overhaul capacity is struggling to keep pace with growing demand, leaving airlines to grapple with grounded aircraft, higher costs and increasingly complex fleet planning.
The number of grounded aircraft powered by Pratt & Whitney GTF engines peaked at 648 in March 2025, equivalent to 28 percent of the global GTF fleet, as operators waited for engine shop visits, spare engines or replacement parts, the report said.
Affected airlines have been forced to retain older aircraft for longer, extend leases or source additional aircraft to maintain capacity, according to the study.
“Engine MRO bottlenecks are disrupting airline operations,” Willie Walsh, IATA director-general, said in a statement.
“Without significant changes, this will only get worse as the fleet of latest-generation single-aisle aircraft grows.”
The warning comes as Airbus and Boeing seek to increase production of narrow-body jets to meet strong travel demand, while airlines continue to modernize fleets with more fuel-efficient aircraft.
In 2024, manufacturers delivered about 2,000 new-generation single-aisle engines, including 1,200 LEAP engines and 800 GTF engines.
Annual deliveries are expected to rise to around 3,700 engines between 2030 and 2040, including roughly 2,500 LEAP engines and 1,200 GTF engines each year, according to the report.
As a result, maintenance demand is forecast to surge sharply over the next decade.
Annual shop visits for LEAP engines are expected to increase from about 600-800 in 2025 to more than 5,000 by 2040, while GTF engine shop visits are projected to rise from around 1,000 to more than 2,000 over the same period.
The report called for greater availability of spare parts, broader access to approved repairs and maintenance information, and increased participation by independent maintenance providers.
IATA also urged manufacturers to adopt more transparent aftermarket practices and ensure fair access to parts, tools and repair capabilities, arguing that greater competition would help alleviate current capacity constraints.
“Resolving today’s disruption is the immediate priority,” Walsh said.
“But long-term resilience will depend on a more transparent, competitive and collaborative aftermarket.”
The findings add to mounting concerns across the aerospace industry over supply-chain constraints that have slowed aircraft deliveries and complicated maintenance planning, even as global air travel demand remains near record levels.
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