AerFin Supplies Overhauled Boeing 777 Landing Gear Boosting Aviation Aftermarket

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

AerFin