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.
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.
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.
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.”
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 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 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.
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.”
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. 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.
What is USM in aviation? Why is landing gear overhaul important for airlines? How does AerFin ensure the quality of overhauled components? What are the main growth drivers for the aviation aftermarket? How is digital transformation impacting the aviation aftermarket?
AerFin’s Overhauled B777-300ER Landing Gear Supply: A Window into the Modern Aviation Aftermarket
AerFin’s Strategic Role in the Aviation Aftermarket
Operational Expertise and Expansion
Boeing 777-300ER: Technical and Market Context
Landing Gear Overhaul: Economic and Operational Drivers
The Rise of Used Serviceable Materials (USM) in Aviation
Market Drivers and Sustainability
Industry Recovery, Growth, and Strategic Initiatives
Conclusion
FAQ
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.
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.
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.
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.
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
ITP Aero to Acquire Aero Norway, Expanding CFM56 MRO Services
ITP Aero signs agreement to acquire Aero Norway, enhancing aftermarket capabilities for CFM56 engines and expanding its European MRO presence.
ITP Aero, a global leader in aerospace propulsion, has signed a binding agreement to acquire Aero Norway, a specialized maintenance, repair, and overhaul (MRO) provider focused on CFM56 engines. According to the company’s official announcement, the transaction is expected to close during the first half of 2026, subject to customary regulatory approvals.
The acquisition represents a significant expansion of ITP Aero’s aftermarket capabilities. By integrating Aero Norway’s facility in Stavanger, Norway, ITP Aero aims to reinforce its status as a leading independent player in the aerospace services sector. The move follows a trajectory of aggressive growth for the Spanish propulsion company since its acquisition by Bain Capital in 22.
Aero Norway operates out of a facility at Sola Airport in Stavanger, employing a workforce of over 200 skilled technicians. The company has established a reputation for high-quality engine maintenance, specifically for the CFM56 engine family, serving a global client base of airlines, lessors, and asset managers.
In its press statement, ITP Aero highlighted that the two companies possess “highly complementary strengths.” The deal combines Aero Norway’s deep expertise in engine overhaul with ITP Aero’s existing engineering capabilities and component repair infrastructure. This synergy is designed to offer a more comprehensive suite of services to the aftermarket sector.
This agreement is the latest in a series of strategic moves by ITP Aero. In 2023, the company acquired BP Aero in the United States and was recently selected to join Pratt & Whitney’s GTF MRO network. These steps are part of a broader “2030 Strategic Plan” which aims to double the size of the business and increase the global workforce by 50% by the end of the decade.
While the press release focuses on corporate synergies, the acquisition underscores a critical trend in the current aviation landscape: the extended dominance of the CFM56 engine. As new-generation engines like the LEAP and GTF face supply chain delays and durability challenges, airlines are keeping older aircraft powered by CFM56 engines in service longer than originally planned.
Industry data suggests that approximately 20,000 CFM56 engines will remain in service through 2025. Consequently, the demand for maintenance shop visits is projected to peak between 2025 and 2027. By acquiring a specialist shop like Aero Norway, ITP Aero is effectively positioning itself to capture high-value work during this period of “structural undersupply” in the narrowbody market. This “Golden Tail”, the long, profitable tail end of an engine program’s lifecycle, provides a stable revenue runway for MRO providers capable of handling heavy overhauls. The crossover point where new-generation engine shop visits outnumber CFM56 visits is not expected until later in the decade, making capacity for legacy engines a premium asset today.
Leadership from both organizations emphasized the value of combining their respective technical strengths. Eva Azoulay, CEO of ITP Aero Group, described the agreement as a key component of the company’s roadmap.
“The signing of this binding acquisition agreement marks a significant milestone in our strategic roadmap. This acquisition reinforces our ambition to become a leading independent player in the aerospace aftermarket.”
, Eva Azoulay, CEO of ITP Aero Group
Neil Russell, CEO of Aero Norway, noted that the merger would unlock synergies beneficial to their customer base.
“By combining the complementary strengths of ITP Aero and Aero Norway, we will unlock significant synergies that enhance our competitiveness and deliver even greater value to our customers.”
, Neil Russell, CEO of Aero Norway
ITP Aero reports that it has tripled its earnings since 2022 and is currently implementing a long-term business plan that spans civil, defense, and MRO segments. The company was advised on legal M&A matters regarding this transaction by Baker McKenzie.
Pending regulatory clearance, the integration of Aero Norway into the ITP Aero Group will finalize in 2026, solidifying the company’s footprint in the European MRO market.
Sources:
ITP Aero to Acquire Aero Norway, Strengthening Position in CFM56 Aftermarket
Strategic Expansion in the MRO Sector
AirPro News Analysis: The “Golden Tail” of the CFM56
Executive Commentary
Future Outlook
Photo Credit: ITP Aero
MRO & Manufacturing
AkzoNobel Invests €50 Million to Upgrade US Aerospace Coatings Facilities
AkzoNobel invests €50 million to expand and modernize aerospace coatings production in Illinois and Wisconsin, enhancing capacity and supply chain resilience.
This article is based on an official press release from AkzoNobel.
AkzoNobel has officially announced a significant investments of €50 million (approximately $52–55 million) to modernize and expand its aerospace coatings capabilities in North America. According to the company’s announcement on December 18, 2025, the project will focus on upgrading its flagship manufacturing facility in Waukegan, Illinois, and establishing a new distribution center in Pleasant Prairie, Wisconsin.
This strategic move aims to increase production capacity and shorten lead times for airline and Maintenance, Repair, and Operations (MRO) customers. By enhancing its supply chain infrastructure, AkzoNobel intends to address the growing demand for air travel and the subsequent need for advanced aerospace coatings.
The investment centers on the Waukegan facility, which currently serves as AkzoNobel’s largest aerospace coatings production site globally. The site employs approximately 200 people and houses a dedicated color center. According to the press release, the capital injection will fund the installation of new machinery and automated processes designed to handle larger batch sizes.
To further optimize operations, the company is relocating its warehousing and distribution activities to a new facility in Pleasant Prairie, Wisconsin. This relocation is intended to free up floor space at the Waukegan plant, allowing for a focus on complex, customized chemical manufacturing.
Patrick Bourguignon, Director of AkzoNobel’s Automotive and Specialty Coatings, emphasized the forward-looking nature of the investment:
“This investment will increase our comprehensive North American supply capability and solidify our position as a frontrunner in the aerospace coatings industry. Demand for air travel is expected to grow significantly… and we want to make sure our customers are able to meet that demand.”
A key component of the upgrade is the introduction of a “Rapid Service Unit” dedicated to faster turnaround times for the MRO market. The company states that the new infrastructure will include a “liquid pre-batch area” and “high-speed dissolvers” to accelerate production.
Martijn Arkesteijn, Global Operations Director for AkzoNobel Aerospace Coatings, noted that these improvements are designed to enhance flexibility for customers: “We’ll be able to provide current and future customers with even more flexibility through the delivery of large batch sizes, better responsiveness to market needs and shorter lead time for color development.”
While AkzoNobel’s announcement focuses on internal efficiency, this investment arrives during a period of intensified competition within the North American aerospace sector. Earlier in 2025, rival manufacturer PPG announced a massive $380 million investment to construct a new aerospace coatings plant in Shelby, North Carolina.
In our view, AkzoNobel’s strategy differs significantly from its competitor’s greenfield approach. Rather than building new capacity from scratch, AkzoNobel is executing a targeted upgrade of existing assets. This “efficiency war” suggests that the company is betting on agility and technology upgrades, specifically the ability to deliver custom colors and small batches quickly via its new Rapid Service Unit, rather than simply expanding raw volume output.
The upgraded facilities are also aligned with the aviation industry’s push for decarbonization. AkzoNobel highlighted that the investment supports the production of its “Basecoat/Clearcoat” systems, which are lighter than traditional coatings. Reducing paint weight is a critical factor for airlines seeking to lower fuel consumption and carbon emissions.
Furthermore, the new automated processes are expected to reduce chemical waste and solvent use. The facility upgrades will likely support the increased production of chromate-free primers, meeting stricter regulatory requirements in both the United States and the European Union.
By localizing more storage and production capacity in North America, AkzoNobel also aims to bolster supply chain resilience, addressing vulnerabilities exposed during the post-pandemic aviation recovery.
AkzoNobel Announces €50 Million Upgrade to US Aerospace Coatings Operations
Strategic Expansion in Illinois and Wisconsin
Operational Efficiency and the “Rapid Service Unit”
AirPro News Analysis: The Competitive Landscape
Sustainability and Technology Integration
Sources
Photo Credit: AkzoNobel
MRO & Manufacturing
GE Aerospace Deploys 180 Engineers for Holiday Flight Operations
GE Aerospace positions 180 Field Service Engineers in 34 countries to prevent aircraft groundings and manage winter maintenance challenges during peak holiday travel.
While millions of travelers settle in for holiday downtime, the global aviation industry enters its most critical operational window. According to AAA projections, approximately 122.4 million Americans traveled 50 miles or more from home during the 2024-2025 holiday season, with air travel seeing a projected 2.3% increase in domestic flyers. Behind this surge lies a largely invisible workforce dedicated to preventing cancellations before they happen.
According to an official press release from GE Aerospace, the company deployed 180 Field Service Engineers (FSEs) to 34 countries specifically to support Airlines customers during this peak period. These engineers are “embedded” directly with airlines and airframers, working on tarmacs and in hangars to mitigate technical risks that could otherwise ground fleets during the busiest weeks of the year.
The role of an FSE goes beyond standard maintenance; it involves proactive problem-solving under strict time constraints. GE Aerospace describes these teams as being on the front lines, ensuring that both passenger jets and cargo freighters remain operational despite the strain of high-cycle usage and winter weather.
Jordan Mayes, a Regional Leader for GE Aerospace Commercial Field Service in Western Europe and Africa, highlighted the intensity of the holiday operational tempo in the company’s statement:
“The sense of urgency is more elevated than normal… And often there are fewer hands to do the work.”
, Jordan Mayes, GE Aerospace Regional Leader
This urgency is driven not just by passenger volume, but by a booming air cargo sector. Industry data indicates that air cargo volumes saw double-digit growth in late 2024, driven by e-commerce demands and shipping disruptions in the Red Sea. Stephane Petter, a Regional Leader for Central/Eastern Europe and Central Asia, noted that the stakes for cargo are often underestimated.
“An issue with a grounded or delayed passenger aircraft might delay 350 people. With a cargo plane, thousands of parcels might be delayed, so the downstream customer impact is potentially greater.”
, Stephane Petter, GE Aerospace Regional Leader
To illustrate the impact of embedded engineers, GE Aerospace shared a specific operational success story involving Alaa Ibrahim, the Middle East regional leader. His team was monitoring a Boeing 787 Dreamliner equipped with GEnx-1B engines. The engineers identified a minor clamp repair that was necessary to keep the engine compliant. The engine was only four cycles (flights) away from a mandatory 500-cycle inspection limit. If the limit was reached without the repair, the aircraft would be grounded, a disastrous outcome during peak holiday scheduling.
Instead of waiting for a forced grounding, Ibrahim’s team identified a six-hour window in the aircraft’s schedule. They performed the inspection and repair proactively, ensuring the aircraft remained available for service without disrupting the airline’s timetable.
Beyond scheduling pressures, FSEs must contend with the physical realities of winter aviation. Industry reports highlight that “cold soak”, where an aircraft sits in freezing temperatures for extended periods, presents unique mechanical challenges. Oil can thicken, and seals can shrink or become brittle.
According to technical data regarding modern engines like the CFM LEAP, specific warm-up protocols are required to thermally stabilize the engine before takeoff power is applied. Maintenance teams often switch to lower-viscosity fluids and rigorously check breather tubes for ice accumulation. If a breather tube freezes due to condensation, it can pressurize the engine and cause seal failures.
The deployment of these 180 engineers highlights a broader shift in aviation maintenance from reactive repairs to predictive intervention. By utilizing digital tools that monitor engine health in real-time, often referred to as “Flight Deck” principles, engineers can detect vibration trends or temperature spikes before they trigger a cockpit warning.
We observe that this strategy is particularly vital during the holidays. When load factors are near 100%, airlines have zero spare aircraft to absorb a cancellation. The ability of FSEs to turn a potential “aircraft on ground” (AOG) event into a scheduled maintenance task during a layover is the difference between a smooth operation and a headline-making travel meltdown.
All Sleigh, No Delay: How Field Service Engineers Keep Holiday Fleets Airborne
The “Invisible Elves” of Aviation
Operational Wins: The GEnx-1B “Save”
Technical Challenges in Winter Operations
AirPro News Analysis: The Shift to Predictive Maintenance
Frequently Asked Questions
Sources
Photo Credit: GE Aerospace
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