MRO & Manufacturing
Embraer Invests $70M in Fort Worth MRO Facility Expansion
Embraer’s new Texas MRO facility increases North American service capacity by 53%, creating 250 jobs and leveraging strategic partnerships for workforce development.
On June 24, 2025, Embraer officially inaugurated its latest commercial Maintenance, Repair, and Overhaul (MRO) facility at Perot Field Fort Worth Alliance Airport, Texas. This move marks a significant strategic investment by the Brazilian aerospace manufacturer in the North American aviation market. With a projected investment of up to $70 million and the creation of approximately 250 new jobs, the facility is poised to enhance Embraer’s service capabilities across the United States by 53%.
The development is not just a business expansion; it reflects broader trends in the aviation industry, including aging fleets, increasing demand for regional jet maintenance, and the integration of advanced technologies like predictive maintenance. Embraer’s decision to expand in Fort Worth aligns with Texas’ growing reputation as a hub for aerospace innovation and infrastructure, often referred to as the “Aviation Capital of Texas.”
With the global MRO market projected to exceed $282 billion in 2025, Embraer’s investment is both timely and calculated. The phased approach, initial operations in a retrofitted hangar followed by a purpose-built facility by 2027, underscores a long-term vision to capture market share and improve service delivery for its growing fleet of E-Jets in North America and beyond.
Embraer’s Fort Worth expansion follows a two-phase implementation strategy. Phase one involves the immediate use of an existing 100,000-square-foot hangar, retrofitted with specialized tooling and maintenance stations. This allows Embraer to begin servicing U.S. operators like American Airlines and SkyWest Airlines without delay. The second phase, scheduled for completion in 2027, includes constructing a new, purpose-built hangar equipped with robotic automation and sustainable design features.
This phased approach not only mitigates financial risks but also enables Embraer to capture immediate maintenance demand while scaling up for long-term capacity. Once fully operational, the combined facilities are expected to handle over 150 heavy maintenance visits annually, significantly boosting Embraer’s service capabilities in the region.
By leveraging its proprietary OEM data and specialized tooling, Embraer positions itself to offer faster turnaround times, up to 15% quicker than third-party providers. This operational efficiency is a critical competitive advantage in a market where aircraft downtime directly impacts airline profitability.
“We will continue working to expand Embraer’s capacity, capability, and footprint in the U.S.”
The $70 million investment includes $45 million for new construction, $15 million for specialized equipment, and $10 million for workforce development. The latter is being executed in partnership with Tarrant County College, which will provide aviation technology training programs tailored to Embraer’s operational needs.
The 250 direct jobs created will offer average annual salaries of $75,000, 35% above the state median for aircraft mechanics. Additionally, the Fort Worth Economic Development Partnership projects 380 indirect jobs in the supply chain and hospitality sectors, contributing an estimated $190 million annually to the regional GDP. This substantial economic footprint underscores the facility’s importance not only to Embraer but also to Fort Worth’s broader industrial ecosystem. The project exemplifies how public-private partnerships can drive regional development while meeting global industry demands.
Parallel to its commercial MRO growth, Embraer is also expanding its executive aviation services. Between 2023 and 2025, the company increased its U.S.-owned service centers for executive jets from three to six, including new facilities in Dallas Love Field and Cleveland.
This dual-track strategy enables operational synergies such as shared supply chains and cross-trained personnel, optimizing resource use and reducing operational costs. It also allows Embraer to tap into higher-margin revenue streams from executive aviation, thereby subsidizing competitive pricing in the commercial MRO sector.
As the executive fleet grows, up 28% since 2020, this integrated approach positions Embraer to serve both market segments effectively, enhancing its overall competitiveness in the aviation services industry.
Embraer’s Fort Worth facility directly challenges established MRO providers like AAR Corp and ST Engineering. By increasing its capacity by 53% and offering OEM-backed services, Embraer leverages its technical edge to capture market share in the regional jet segment.
The expansion also strengthens Embraer’s position against Airbus and Boeing, whose service divisions have seen rapid growth. With OEM access to maintenance data and proprietary tooling, Embraer can offer more efficient services, drawing customers away from third-party providers.
Industry analysts predict that the Fort Worth facility could capture up to 15% of the U.S. regional jet maintenance market by 2030, translating to an estimated $340 million in annual revenue based on current market size projections.
The demand for certified aircraft technicians is expected to rise sharply, with North America projected to face an 18,000-mechanic shortage by 2030. Embraer’s partnership with Tarrant County College aims to address this gap through specialized training programs that incorporate virtual reality simulations and proprietary Embraer curricula. This approach not only ensures a steady pipeline of skilled labor for Embraer but may also serve as a model for the broader industry. With American Airlines and Lockheed Martin already operating large technical workforces in the region, competition for talent is fierce, potentially driving up wages and setting new benchmarks for technical education.
By investing in workforce development, Embraer is not just filling immediate roles but also contributing to the long-term sustainability of the aviation maintenance sector in Texas and beyond.
AllianceTexas, where the facility is located, offers strategic advantages such as proximity to BNSF Railway’s intermodal hub and direct highway access. This enables just-in-time delivery of parts and components, reducing aircraft downtime and improving service efficiency.
The facility includes 30,000 square feet dedicated to component repair, allowing Embraer to internalize services previously outsourced. This vertical integration aligns with industry trends favoring consolidated service providers capable of offering end-to-end maintenance solutions.
Such infrastructure optimization not only enhances operational efficiency but also positions Embraer as a preferred partner for airlines seeking reliable, comprehensive maintenance services within tight operational windows.
Embraer’s Fort Worth MRO facility is more than an infrastructure project, it’s a strategic move that aligns with global aviation trends. From increased fleet sizes to aging aircraft and the rise of predictive maintenance technologies, the facility is well-positioned to serve the evolving needs of the aviation industry.
Looking ahead, Embraer is likely to explore further innovations such as AI-driven maintenance analytics, sustainable retrofit solutions for hybrid-electric aircraft, and potential cargo conversion services for its E-Jet family. These developments could further solidify Embraer’s role as a leader in aviation services and technology integration.
What is the purpose of Embraer’s new MRO facility in Fort Worth? How much is Embraer investing in the Fort Worth facility? How many jobs will be created? When will the second hangar be completed? What are the long-term industry implications?
Embraer Opens New MRO Facilities in Fort Worth: A Strategic Leap in North American Aviation
Strategic Expansion of Embraer’s MRO Network
Phased Development and Operational Strategy
Economic and Employment Impact
Executive Aviation and Synergy with Commercial Operations
Implications for the North American Aviation Market
Shifting Competitive Landscape
Workforce Development and Training Innovation
Supply Chain and Infrastructure Optimization
Conclusion and Future Outlook
FAQ
To expand its maintenance, repair, and overhaul capabilities for commercial jets in North America, increasing service capacity by 53%.
Up to $70 million, including construction, equipment, and workforce development initiatives.
Approximately 250 direct aviation jobs, with an additional 380 indirect jobs expected in related sectors.
The second phase of the project, including a new hangar, is scheduled for completion in 2027.
Improved service efficiency, enhanced workforce development, and stronger competitive positioning in the regional jet and executive aviation segments.
Sources
Photo Credit: Embraer