MRO & Manufacturing
AerFin Supplies Overhauled Boeing 777 Landing Gear Boosting Aviation Aftermarket
AerFin delivers overhauled Boeing 777-300ER landing gear, highlighting growth in the aviation aftermarket and sustainable MRO solutions.
AerFin’s Overhauled B777-300ER Landing Gear Supply: A Window into the Modern Aviation Aftermarket
The aviation industry is in the midst of a remarkable transformation, driven by a post-pandemic recovery, rapid technological advancement, and a growing focus on sustainability. At the heart of this evolution lies the aviation aftermarket, the ecosystem responsible for maintaining, repairing, and overhauling aircraft and their components. AerFin’s recent supply of an overhauled Boeing 777-300ER landing gear set to a major international carrier is more than a routine transaction; it is a testament to the sector’s rising sophistication and strategic importance. This event provides a lens through which we can examine critical shifts in aircraft maintenance, the used serviceable materials (USM) market, and the operational realities faced by airlines worldwide.
With passenger numbers forecasted to surpass pre-pandemic records and the aviation MRO (maintenance, repair, and overhaul) market growing steadily, the demand for cost-effective and reliable solutions has never been higher. The overhaul and redeployment of high-value components like landing gear not only help airlines manage costs but also facilitate sustainable practices by extending the life of existing assets. AerFin’s role in this domain highlights how specialized providers are shaping the future of aviation maintenance, balancing economic, operational, and environmental imperatives.
In this article, we explore AerFin’s position in the global aftermarket, the technical and commercial context of the Boeing 777-300ER, and the broader trends influencing the aviation landing gear and USM markets. By analyzing recent industry developments and strategic initiatives, we provide a comprehensive view of the forces at play and the implications for the future of aviation support services.
AerFin’s Strategic Role in the Aviation Aftermarket
Founded in 2010 and headquartered in Caerphilly, UK, AerFin has become a leading aviation asset specialist, offering services that span aircraft and engine leasing, part sales, and comprehensive MRO solutions. With 135 employees and annual revenues exceeding $100 million, AerFin’s business model is built around the acquisition, teardown, refurbishment, and resale of aircraft components, positioning the company as a vertically integrated aftermarket supplier.
Recent years have seen AerFin expand its global footprint, opening offices in key aviation hubs such as Singapore, Miami, and Dublin. The Singapore branch, launched in 2024 and led by industry veteran Paul Ashcroft, reflects AerFin’s strategic focus on the Asia-Pacific region, a market expected to experience significant fleet growth and increased demand for efficient fleet transitions and retirements. The Miami facility serves as a vital logistics and distribution center, storing harvested parts from aircraft teardowns and supporting urgent customer requirements across the Americas.
In January 2025, AerFin inaugurated its new global headquarters in Newport, South Wales. This 116,000-square-foot, BREEAM Excellent-accredited facility doubles the company’s engine MRO capacity, enabling up to 200 quick-turn shop visits annually. The site features advanced warehouse automation, diagnostic tools, and sustainable practices such as solar panels and rainwater harvesting, underlining AerFin’s commitment to operational excellence and environmental responsibility.
Operational Expertise and Expansion
AerFin’s success is underpinned by its ability to provide end-to-end solutions for airlines, MROs, and lessors. By managing the full lifecycle of aircraft components, from acquisition and teardown to overhaul and resale, the company offers flexibility and rapid response to customer needs. This is particularly important in an industry where unscheduled downtime can result in significant financial losses for operators.
The company’s expansion into widebody aircraft teardown, including the recent dismantling of a Boeing 777-300ER previously operated by Japan Airlines, has strengthened its USM inventory and ability to support high-value, complex components. These strategic moves ensure a steady supply of certified, overhauled parts for a global customer base.
Strategic Partnerships further enhance AerFin’s capabilities. Collaborations with organizations such as Iberia Maintenance and logistics specialist B&H Worldwide extend AerFin’s reach and service quality, allowing for efficient, compliant, and timely delivery of critical components worldwide. The company’s digital transformation initiative, Project ‘AerFinity’, developed in partnership with Acumen Aviation, exemplifies its commitment to leveraging technology for predictive analytics and dynamic supply chain management.
“The company’s new headquarters will double engine MRO capacity and enable up to 200 quick-turn shop visits annually, supporting rapid turnaround and increased industry demand.”
Boeing 777-300ER: Technical and Market Context
The Boeing 777-300ER is one of the most successful widebody aircraft in commercial aviation, with 799 delivered and more than 844 ordered globally. Its extended range, high capacity (typically 301–450 passengers), and operational efficiency make it a staple of long-haul fleets. Major Airlines such as Emirates, United, Qatar Airways, Air France, American Airlines, and Cathay Pacific operate large numbers of these aircraft, underscoring its global significance.
As a long-haul workhorse, the 777-300ER operates on routes requiring high reliability and robust support infrastructure. Its landing gear system, engineered for heavy loads and long cycles, is a complex and high-value component. The cost of a complete landing gear set for a 777 can exceed $7 million, making the decision to overhaul versus replace a critical financial consideration for operators.
Advances in landing gear technology, including lightweight materials, advanced hydraulics, and digital monitoring, have improved performance and reliability, but also increased the specialization required for maintenance. Predictive maintenance and real-time monitoring now enable more precise scheduling, reducing unscheduled groundings and optimizing fleet availability.
Landing Gear Overhaul: Economic and Operational Drivers
Landing gear overhaul is a significant expense, typically ranging from 10% to 20% of the cost of a new set. For airlines, choosing to overhaul rather than replace landing gear can result in substantial savings, particularly when working with certified providers like AerFin. Overhauled gear must meet stringent regulatory standards, ensuring safety and reliability are maintained.
The global landing gear repair and overhaul market is valued at approximately $1.8–3.5 billion in 2024, with projections reaching up to $5.2 billion by 2033. Growth is driven by fleet expansion, increased air travel demand, and the rising average age of commercial aircraft. Emerging markets in Asia-Pacific are particularly significant, with China expected to operate over 6,000 commercial aircraft by 2030.
Regulatory frameworks established by authorities such as the FAA and EASA mandate rigorous inspection, testing, and documentation for overhauled components. The use of advanced digital tracking and verification technologies has further improved transparency and confidence in the overhaul process.
“Landing gear overhaul costs typically range from 10% to 20% of the price of a new set, offering airlines significant savings while maintaining safety and reliability.”
The Rise of Used Serviceable Materials (USM) in Aviation
The USM market has emerged as a vital component of the aviation aftermarket, offering airlines and MROs an economical and sustainable alternative to new OEM parts. Market research indicates that the USM sector will reach between $10.3 and $11.1 billion by 2032, growing at a CAGR of 4.1–4.5%. This growth is underpinned by the economic benefits of USM, as well as increasing acceptance of circular economy principles within the industry.
Engine components represent the largest segment of the USM market, reflecting their high value and the cost savings they offer. Avionics are the fastest-growing segment, as rapid technological evolution creates opportunities to upgrade systems using newer, pre-owned components. Landing gear, given its complexity and cost, is also a significant focus for USM providers.
Quality assurance is paramount in the USM market. Regulatory standards require comprehensive certification, traceability, and documentation. The adoption of digital and blockchain-based tracking systems has enhanced supply chain integrity, addressing historical concerns about the reliability of used components.
Market Drivers and Sustainability
Cost reduction remains the primary driver for USM adoption, particularly among low-cost carriers and smaller airlines. By sourcing overhauled and certified components, operators can extend aircraft lifespans, optimize maintenance budgets, and reinvest savings into other operational priorities.
Sustainability is an increasingly important consideration. The reuse and refurbishment of aircraft components reduce waste and resource consumption, aligning with broader industry and societal goals. AerFin’s focus on sustainable practices, including environmentally friendly headquarters and teardown operations, exemplifies this shift.
Strategic partnerships, such as AerFin’s collaboration with Iberia Maintenance, further amplify the value of USM by combining inventory, technical expertise, and global reach. These alliances enable more flexible and responsive support for operators navigating complex and dynamic market conditions.
“The USM market is projected to reach $11.1 billion by 2032, driven by cost savings, regulatory confidence, and growing emphasis on sustainability.”
Industry Recovery, Growth, and Strategic Initiatives
The aviation industry’s recovery from the COVID-19 pandemic has been both rapid and profound. Global passenger numbers are expected to reach a record 4.96 billion in 2024, with airline revenues and net profits rebounding accordingly. This resurgence has fueled demand for aftermarket services, as airlines seek to restore and expand operations while controlling costs.
The commercial aircraft MRO market is forecast to grow from $118.1 billion in 2025 to $163.4 billion by 2035, with engine and landing gear MRO representing key service types. The anticipated retirement of older aircraft in 2025 will further boost the availability of USM components, supporting ongoing fleet maintenance and renewal.
In response, AerFin has invested in capacity expansion, digital transformation, and brand repositioning. The company’s new headquarters, enhanced teardown activities, and leadership transition to CEO Simon Goodson position it for continued growth and industry leadership. These developments reflect a broader trend toward integrated, technology-enabled, and sustainable aftermarket solutions.
Conclusion
AerFin’s supply of an overhauled Boeing 777-300ER landing gear set to a major international carrier encapsulates the strategic, technical, and commercial forces shaping the modern aviation aftermarket. As airlines confront rising demand, cost pressures, and sustainability imperatives, the role of specialized providers in delivering reliable, certified, and economical solutions becomes ever more critical.
With the USM and landing gear overhaul markets set for continued expansion, and with industry recovery fueling new opportunities, AerFin’s comprehensive approach, combining operational expertise, global reach, strategic partnerships, and technological innovation, offers a blueprint for success in the evolving landscape of aviation support services. The future will likely see further integration of digital tools, increased focus on sustainability, and deeper collaboration across the aftermarket value chain.
FAQ
What is USM in aviation?
USM stands for Used Serviceable Material. These are aircraft parts that have been previously used but have been overhauled, inspected, and certified to meet regulatory standards for reuse in active fleets.
Why is landing gear overhaul important for airlines?
Overhauling landing gear allows airlines to extend the life of expensive components, reduce costs compared to buying new, and ensure compliance with safety regulations. It is particularly critical for widebody aircraft like the Boeing 777-300ER due to the high value and complexity of their landing gear systems.
How does AerFin ensure the quality of overhauled components?
AerFin follows rigorous inspection, testing, and documentation processes in line with FAA and EASA regulations. The company also leverages advanced digital tracking to ensure full traceability and certification of all overhauled parts.
What are the main growth drivers for the aviation aftermarket?
Growth is driven by increasing global fleet sizes, rising air travel demand, the economic benefits of USM, technological advancements in maintenance, and a growing emphasis on sustainability and circular economy practices.
How is digital transformation impacting the aviation aftermarket?
Digital tools enable predictive maintenance, real-time supply chain management, and enhanced traceability, allowing for more efficient operations and better customer support in the aftermarket sector.
Sources
Photo Credit: AerFin
MRO & Manufacturing
Baxter Aerospace Invests $19.55M in Utah Manufacturing Facility
Baxter Aerospace expands into Washington County, Utah with a $19.55M facility to scale UAS and satellite comms production.
Baxter Aerospace will invest $19.55 million to lease and equip a new manufacturing facility in Washington County, Utah, transitioning its unmanned aircraft and communications systems from prototype development into full-scale production.
The expansion, announced in an October 8, 2026, press release by the Utah Governor’s Office of Economic Development (GOED), is projected to create 90 high-paying jobs over the next five years while strengthening the state’s aerospace and defense industrial base.
Transitioning to full-scale production
The new facility in Washington City will feature high-capacity infrastructure, specialized testing spaces, and security systems. This site is designed to support mission-critical work across aerospace, defense, satellite communications, autonomous aircraft, and public safety.
Baxter Aerospace CEO Jeff Baxter stated that expanding in southern Utah allows the company to increase manufacturing capacity and support growing customer needs. He noted the company is prepared to help shape the region’s aerospace future.
The project is backed by a Rural Economic Development Tax Increment Financing (REDTIF) post-performance tax credit approved by the GOED. Under the agreement, Baxter Aerospace can earn a rebate of up to 30% on new state revenues generated over the five-year term, capped at $456,939.
State officials project the expansion will generate $20,758,160 in new state wages and $1,523,131 in new state tax revenue during that period. GOED Commissioner Jefferson Moss noted that the investment signals Utah’s economic future is fueled by frontier innovation. Washington County Commissioner Adam Snow added that the expansion connects local talent with emerging aerospace opportunities.
Scaling the BA-1 Dragonfly and defense portfolio
The manufacturing expansion follows a period of steady growth for the St. George-based defense and aerospace innovator. Brothers Jeff and Michael Baxter founded the company in 2015 following a severe Oregon wildfire, focusing their initial efforts on real-time sensing, resilient communications, and autonomous systems for emergency response and defense applications.
The company’s flagship aerospace product is the BA-1 Dragonfly. The Dragonfly is a Group 3 vertical takeoff and landing (eVTOL) unmanned aircraft system designed for intelligence, surveillance, and reconnaissance (ISR) missions, featuring over 12 hours of endurance.
Alongside the BA-1 Dragonfly, Baxter Aerospace produces deployable broadband satellite communications kits that utilize low Earth orbit (LEO) networks. The company also manufactures precision components for the fusion and nuclear energy sectors.
To support the scaling of these product lines, Baxter Aerospace secured a $6 million Series A funding round in July 2025. The capital was raised from the Department of Defense (DoD) Accelerator fund, managed by Accuidity Capital Management, specifically to accelerate production of the Dragonfly system and the deployable communications kits. The new Washington County facility represents the physical infrastructure required to execute that production scale-up between late 2026 and 2031.
Photo Credit: Utah Governor’s Office of Economic Development
MRO & Manufacturing
IAI 777-300ERSF P2F Conversions Launch in North America
The first Boeing 777-300ER for P2F conversion in North America arrives at Ascent Aviation Services in Marana, Arizona.
The first Boeing 777-300ER slated for passenger-to-freighter (P2F) conversion in North America arrived at Ascent Aviation Services in Marana, Arizona, on October 22, 2026. The induction marks the regional launch of the Israel Aerospace Industries (IAI) modification program for the widebody twinjet.
The arrival of the World Star Aviation aircraft initiates operations at a newly expanded site designed to increase global capacity for the Boeing 777-300ERSF program, according to a joint press release issued by the companies.
Expanding global conversion capacity
Ascent Aviation Services, an independent aircraft aftermarket service provider and Federal Aviation Administration (FAA) Class IV Part 145 certified repair station, will operate two parallel conversion lines at its Pinal Air Park campus. To accommodate the Boeing 777-300ERSF program, the company invested $70 million to construct two 90,000-square-foot widebody hangars. Ascent broke ground on the facilities on March 29, 2024, effectively tripling the site’s hangar capacity.
“The launch of Boeing 777-300ERSF conversions in North America marks an important milestone for IAI’s global conversion program,” Yaacov Berkovitz, executive vice president and general manager of IAI Aviation Group, stated in the release. “Together with Ascent Aviation Services, we are expanding production capacity and bringing our conversion capabilities closer to customers in the region.”
Ascent Aviation Services chief executive officer David Querio noted that the induction represents the beginning of a long-term partnership with IAI, with multiple Boeing 777-300ERSF conversions planned for the Marana site.
“Our vision is to shape the future of aviation by turning engineering innovation into lasting value for our customers,” IAI president and chief executive officer Guy Bar Lev added. “Passenger-to-freighter conversions are a key part of that vision, extending the productive life of aircraft and helping airlines adapt to changing market needs.”
World Star Aviation’s fleet strategy
The inaugural aircraft belongs to World Star Aviation, a full-service aircraft and engine lessor headquartered in London. The company specializes in mid-to-late life assets and manages a portfolio of approximately 150 aircraft and engines. This includes 60 narrowbody and widebody freighters currently on lease to cargo operators globally.
World Star Aviation partner Yoyo Allalouf cited the strength of the IAI program during a critical period for widebody passenger-to-freighter production as the primary driver for their selection.
“IAI’s dominance in the widebody P2F space, demonstrated by its Boeing 747 and 767 programs, together with our long-standing relationship, underpinned our decision to choose IAI for the 777-300ERSF,” added Garreth Slevin, partner at World Star Aviation.
The rise of the “Big Twin” freighter
The Boeing 777-300ERSF program, marketed as “The Big Twin,” launched on October 22, 2019, as a joint venture between IAI and GECAS, which was subsequently acquired by AerCap. It remains the only certified P2F conversion program for the Boeing 777-300ER.
The converted freighter offers 25 percent more cargo volume than a production Boeing 777-200LRF and 15 percent more volume than a Boeing 747-400BCF. This capacity positions the aircraft as a direct replacement for aging Boeing 747-400 and McDonnell Douglas MD-11 freighter fleets.
IAI brings over 50 years of experience to the program, having delivered more than 350 converted cargo aircraft across Boeing 747, 767, 737, and Airbus A330 platforms. The company currently holds a dominant market share in medium-size freighter conversions, particularly with the Boeing 767.
The 777-300ERSF recently transitioned from certification into commercial service. In August 2026, Challenge Group took delivery of its second 777-300ERSF, which marked the fifth redelivery of the type across the industry for the year.
AirPro News analysis
We view the activation of the Marana conversion lines as a critical step in maturing the Boeing 777-300ERSF program. By establishing a North American footprint, IAI mitigates geographic bottlenecks and provides operators with a domestic option for heavy modifications. The $70 million infrastructure investment by Ascent Aviation Services indicates strong long-term confidence in the widebody conversion market, even as the air cargo sector normalizes following pandemic-era peaks. As legacy quad-engine and tri-engine freighters approach mandatory retirement or become economically unviable, the availability of parallel conversion lines in the United States ensures IAI can capture a significant share of the impending widebody replacement cycle.
Photo Credit: IAI
MRO & Manufacturing
Cirrus Aircraft Breaks Ground on $8M Engine Run-Up Center
Cirrus Aircraft begins construction on a 15,000-sq-ft Engine Run-Up Center in Duluth, MN, set to open summer 2027.
Cirrus Aircraft has commenced construction on an $8 million, 15,000-square-foot Engine Run-Up Center in Duluth, Minnesota, moving critical engine testing and fuel calibration processes into a year-round, climate-controlled environment.
The new facility, detailed in a company press release on October 23, 2026, is designed to support the certification process for the SR Series, Vision Jet, and TRAC10 aircraft while reducing noise at the surrounding airport.
Centralizing certification operations
The Engine Run-Up Center will consolidate several final-phase manufacturing steps into a single enclosed building. The facility will house two calibration stalls dedicated to engine setup and testing, utilizing an 8-foot exhaust collector to ventilate the spaces. A separate climate-controlled control room will allow technicians to conduct data analysis during the testing phase.
In addition to the testing stalls, the building will include two stalls specifically engineered for fueling and defueling aircraft. These areas incorporate specialized fire protection systems and are designed to meet requirements for handling flammable fluids.
Cirrus Chief Executive Officer Zean Nielsen stated that engine run-ups and fuel system calibration are essential processes across aircraft manufacturing. He noted that the modern facility will allow the company to streamline these critical operations, improve efficiency, and provide team members with a dedicated environment to perform the work.
Expanding the Duluth manufacturing footprint
The new testing center adds to an existing corporate footprint that exceeds 1.3 million square feet. The majority of this infrastructure is located in Duluth, which serves as the primary production hub for the manufacturer.
Founded in 1984 and now publicly traded on the Hong Kong Stock Exchange, Cirrus has manufactured more than 12,000 SR Series piston aircraft and Vision Jets to date. The groundbreaking follows closely on a major program milestone for the company. On October 21, 2026, Cirrus celebrated the 10-year anniversary of Federal Aviation Administration (FAA) type certification for the Vision Jet, the first single-engine personal jet to reach the market.
Patrick Waddick, President of Innovation & Operations at Cirrus, highlighted the scale of the company’s historical output in Duluth. He noted that the new facility expands a footprint where the company has produced its entire fleet of over 12,000 aircraft, adding that the manufacturer has spent decades challenging conventions through innovations that transform personal aviation.
Project timeline and operational impact
Construction on the Engine Run-Up Center is underway, with the facility expected to open and become fully operational by the summer of 2027. By moving engine testing indoors, the company anticipates a reduction in noise levels for the surrounding airport environment, a common challenge for manufacturers conducting high-power engine runs on open ramps.
The $8 million investment reflects broader efforts by the airframer to scale production capabilities in response to market requirements. Nielsen indicated that as the company continues to grow, investments in manufacturing infrastructure position Cirrus to meet customer demand while maintaining high standards of quality and safety.
Photo Credit: Cirrus Aircraft
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