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IATA Reports $11 Billion Aerospace Supply Chain Cost for Airlines in 2025

IATA projects aerospace supply chain issues will cost airlines $11 billion in 2025, driven by delays, aging fleets, and geopolitical challenges.

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This article is based on an official press release from the International Air Transport Association (IATA) and supplementary industry data.

Aerospace Supply Chain Crisis to Cost Airlines $11 Billion in 2025

The global aviation industry is facing a severe “structural mismatch” between demand and production capacity that shows no signs of resolving before the next decade. According to a critical update released on December 9, 2025, by the International Air Transport Association (IATA), persistent supply chain bottlenecks are projected to cost airlines more than $11 billion in 2025 alone.

Despite a slight increase in aircraft deliveries toward the end of the year, the industry remains constrained by a deficit of at least 5,300 aircraft, a “missing fleet” that has forced carriers to fly older, less efficient jets far longer than planned. A joint study conducted by IATA and consultancy Oliver Wyman suggests that while demand for travel remains robust, the industrial base supporting aviation is fragile, with normalization not expected until the 2031–2034 timeframe.

At AirPro News, we are closely monitoring how these disruptions are reshaping airline economics. The data indicates that the inability to secure new “metal” is no longer just an operational headache; it has become a massive financial drain that is stalling sustainability goals and driving up costs for passengers.

Breaking Down the $11 Billion Financial-Results Hit

The IATA and Oliver Wyman study provides a granular look at where the money is being lost. The $11 billion figure for 2025 is not a monolith but a composite of inefficiencies driven by the need to keep aging fleets airborne.

  • Fuel Inefficiency ($4.2 billion): This is the largest single cost driver. Because airlines cannot replace older jets with new neo, MAX, 787, or A350 models, they are burning significantly more fuel. Fuel efficiency improvements have stagnated at just 0.3% in 2025, a sharp drop from the historical average of 2.0% per year.
  • Maintenance Costs ($3.1 billion): Older airframes and engines require more frequent and expensive care.
  • Engine Leasing ($2.6 billion): Leasing rates have surged 20–30% since 2019. Furthermore, shop visits for engines are taking longer due to parts shortages, forcing airlines to lease spare engines for extended periods.
  • Inventory Stockpiling ($1.4 billion): To mitigate the risk of being grounded by a missing widget, airlines are holding significantly more spare parts inventory than usual.

The “Missing Fleet” and Production Stalls

The scale of the backlog is historic. According to the data released, the global order backlog has surpassed 17,000 aircraft. This represents nearly 60% of the active global fleet, a ratio that historically hovers between 30% and 40%. At current production rates, clearing this backlog would take approximately 12 years.

Consequently, the average age of the global fleet has reached a record high of 15.1 years. The situation is particularly acute in the cargo-aircraft sector, where the average aircraft age is now 19.6 years. Passenger-to-freighter (P2F) conversions are stalling because airlines are refusing to retire passenger jets, keeping them in service to meet travel demand rather than releasing them for conversion.

Geopolitical and Industrial Headwinds

While the pandemic created the initial deficit, new challenges in 2024 and 2025 have exacerbated the situation. Industry analysis points to escalating trade tensions between the United States and China as a major disruptor. Tariffs on critical raw materials like aluminum and titanium, along with retaliatory measures affecting aircraft deliveries, have severed established supply lines.

Furthermore, labor shortages remain a critical bottleneck. A lack of skilled workers in engine and component manufacturing is preventing suppliers from ramping up production to meet Original Equipment Manufacturer (OEM) targets. As a result, airframe production is outpacing engine production, leading to “gliders”, completed jets sitting parked without engines, accumulating at production facilities.

Industry Reaction and Strategic Outlook

The consensus among leadership is that the industry must adapt to a long-term environment of scarcity. Willie Walsh, the Director General of IATA, emphasized the breadth of the impact in his statement regarding the report.

“Airlines are feeling the impact… across their business. Higher leasing costs, reduced scheduling flexibility, delayed sustainability gains, and increased reliance on suboptimal aircraft types are the most obvious challenges… No effort should be spared to accelerate solutions before the impact becomes even more acute.”

Willie Walsh, Director General, IATA

Oliver Wyman’s analysis supports this view, warning that the supply-demand mismatch is structural. They urge the industry to adopt “aftermarket best practices,” essentially advising airlines to become experts in extending the life of existing assets rather than banking on new deliveries to solve their problems.

Proposed Solutions

To mitigate the crisis, IATA and Oliver Wyman have outlined a roadmap focused on efficiency and transparency:

  • MRO Reform: The industry is calling for a reduction in dependence on OEM-controlled licensing. Opening up the Maintenance, Repair, and Overhaul (MRO) market to more third-party repairs could speed up the sourcing of Used Serviceable Materials (USM).
  • Data Sharing: Creating shared platforms for supply chain visibility could help manufacturers spot risks, such as a raw material shortage at a Tier-3 supplier, before they halt a major assembly line.
  • Predictive Maintenance: Leveraging AI to predict part failures can optimize the use of scarce inventory, ensuring parts are available exactly when needed.

AirPro News Analysis

The data presented by IATA highlights a paradox in modern aviation: demand is back, but the physical infrastructure to support it is fracturing. The stagnation in fuel efficiency (0.3% vs the expected 2.0%) is perhaps the most damaging long-term consequence. For years, the industry’s net-zero roadmap relied heavily on the continuous introduction of fuel-efficient technology. With that pipeline clogged, airlines may face increased regulatory pressure and higher carbon costs, further squeezing margins.

Additionally, the shift in leverage toward MRO providers and lessors is undeniable. With new aircraft unavailable, those who control the existing stock of engines and spare parts hold the keys to the kingdom. We expect this to drive a wave of consolidation or strategic partnerships in the aftermarket sector throughout 2026.

Sources

Sources: IATA Press Release (Dec 9, 2025); IATA & Oliver Wyman Joint Study (2025); Industry Research Reports (Aviation Week, Leeham News).

Photo Credit: IATA

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FAA Announces $1.776 Billion Airport Infrastructure Grants

FAA and DOT award $1.776B in airport grants across 46 states for runway, taxiway, and safety upgrades.

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On July 2, 2026, the Federal Aviation Administration (FAA) and the U.S. Department of Transportation (DOT) announced $1.776 billion in infrastructure grants distributed across 46 states to fund runway rehabilitations, taxiway construction, and safety upgrades.

The specific funding amount was selected to symbolically align with the United States Semiquincentennial, marking America’s 250th anniversary. According to an FAA press release, the investments are designed to modernize the travel experience and ensure the national airspace system is prepared for future demand.

“What better way to celebrate America than investing in its future. We’re ushering in the Golden Age of Transportation and rebuilding our airport infrastructure is critical to making that vision a reality. Under President Trump’s leadership, we are building an aviation system worthy of our country’s incredible history,” U.S. Transportation Secretary Sean P. Duffy stated in the release.

FAA Administrator Bryan Bedford noted that the agency is prioritizing rapid and efficient grant issuance. Bedford stated the funding “modernizes the travel experience for American families, ensuring our Airports are safe and ready for the future.”

Major airport allocations across the United States

The grant program directs substantial capital to several major hubs for pavement and lighting projects. Denver International Airport (DEN) received the largest single allocation highlighted in the announcement, securing $88.8 million for pavement projects. In the Pacific Northwest, Boise Air Terminal/Gowen Field (BOI) was awarded $74 million to rehabilitate its runway, expand the apron, and upgrade visual guidance lights.

Other significant awards include $62.4 million for Baltimore/Washington International Thurgood Marshall Airport (BWI) to rehabilitate its runway and associated lighting systems, and $62.2 million for Houston William P. Hobby Airport (HOU) to support runway construction.

Additional funding targets infrastructure at coastal and tourist hubs. John F. Kennedy International Airport (JFK) received $47.6 million for taxiway construction and the reconstruction of an aircraft rescue and firefighting building. Orlando International Airport (MCO) secured $36 million for terminal, taxiway, and lighting rehabilitation, while Oakland International Airport (OAK) was granted $28.1 million for taxiway rehabilitation.

Broader modernization initiatives

The July 2, 2026, grant announcement follows a series of recent infrastructure and regulatory actions by the DOT and FAA. Secretary Duffy and Administrator Bedford have prioritized public visibility into these upgrades. In May 2026, the agencies launched the “Modern Skies” website, a platform designed to provide transparency on more than 10,000 air traffic control modernization projects across the national airspace system.

The infrastructure funding also ties into the DOT’s broader commemorative efforts. In March 2026, Secretary Duffy introduced the “Freedom Moves You” campaign, an initiative bringing historical imagery to major transportation hubs, including JFK, in conjunction with the America 250th celebrations.

On the regulatory front, the FAA recently advanced new operational frameworks. On June 30, 2026, the agency proposed rules to establish noise-based certification standards for civil supersonic flight over the United States, aiming to facilitate the operation of next-generation aircraft without producing a sonic boom.

AirPro News analysis

We view the symbolic $1.776 billion figure as a clear messaging strategy from the DOT, linking routine but necessary infrastructure spending to the broader national narrative of the Semiquincentennial. While the dollar amount is stylized for the occasion, the underlying projects address critical deferred maintenance at major hubs like DEN and JFK. The focus on runway and taxiway rehabilitation reflects an ongoing necessity to maintain safety margins and operational efficiency as passenger volumes continue to test the limits of existing airport infrastructure.

Sources: Source Name, Source Name, Source Name, Source Name

Photo Credit: Stock Image

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AirAsia MOVE Adds Four Direct Airline Partners in Q2 2026

AirAsia MOVE expands its direct airline roster to 75 carriers with Oman Air, Uzbekistan Airways, FitsAir, and Hainan Airlines.

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AirAsia MOVE expanded its online travel agency (OTA) platform on June 29, 2026, integrating Oman Air, Uzbekistan Airways, FitsAir, and Hainan Airlines as direct booking partners.

The integration increases the platform’s direct airline roster to 75 global carriers. According to a press release issued by Capital A, the move supports the company’s Strategy to scale its distribution capabilities across the Middle East, Central Asia, South Asia, and China, transitioning the application further beyond its core AirAsia low-cost network.

Expanding global connectivity

The four new carriers represent a mix of full-service and low-cost operators. By establishing direct Partnerships, AirAsia MOVE bypasses third-party aggregators for these specific airlines. This direct technical link typically allows travel platforms to offer tighter integration of ancillary services, seat selection, and branded fare products.

AirAsia MOVE Chief Executive Officer Nadia Omer stated that expanding the network offering remains core to the platform’s mission as a flights-first OTA, noting that traveler demands across the Association of Southeast Asian Nations (ASEAN) region are evolving toward single-platform solutions.

“Securing the trust of major carriers like Oman Air, Uzbekistan Airways, FitsAir, and Hainan Airlines, particularly amidst ongoing macroeconomic headwinds and volatility, is a powerful testament to the commercial strength of the MOVE ecosystem and the regional reach we deliver to our partners,” Omer said.

Beyond its 75 direct partners, the platform currently offers inventory from approximately 700 additional airlines through authorized third-party suppliers. The application also provides access to more than one million hotels globally.

Strategic ecosystem growth

The second-quarter airline additions follow a series of regional partnerships aimed at broadening the application’s utility and market penetration. On June 24, 2026, AirAsia MOVE signed a collaboration agreement with the Tourism Authority of Thailand. The partnership is designed to support the country’s tourism growth initiatives through the OTA’s digital marketing and booking capabilities.

The company is also exploring alternative payment technologies to support its expansion into emerging markets. On May 25, 2026, AirAsia MOVE signed a letter of intent with Intebix and the Solana Foundation. The agreement focuses on exploring the integration of a Tenge-denominated stablecoin on the Solana blockchain, intended to expand digital payment options for users in Kazakhstan.

AirPro News analysis

We view AirAsia MOVE’s continued accumulation of direct airline partners as a necessary step in its transition from a captive airline application to a standalone OTA competitor. While offering 700 airlines via third-party suppliers provides necessary breadth, direct integrations yield better margins and allow the platform to merchandise partner flights more effectively. Securing full-service carriers like Oman Air and Hainan Airlines also helps diversify the platform’s user base, attracting demographics beyond the budget-conscious travelers traditionally associated with the core AirAsia brand.

Sources: Capital A Newsroom (Press Release)

Photo Credit: Capital A

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Portland Airport Completes $2 Billion Terminal Expansion

PDX completes its $2B, 1M sq ft terminal expansion, doubling capacity with a mass timber roof and all-electric heat pump system.

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The Port of Portland and ZGF Architects LLP officially opened the second and final phase of the $2 billion main terminal expansion at Portland International Airports (PDX) on June 30, 2026. The completion of the one million-square-foot project doubles the passenger capacity of the airport and concludes five years of phased construction.

According to a press release issued by ZGF Architects, the expansion represents the largest public infrastructure project in Oregon’s history. The facility remained fully operational throughout the construction process, which was executed by a project team including the Hoffman Skanska Joint Venture, KPFF, Arup, PAE, and Swinerton.

Architectural and structural engineering features

A defining feature of the renovated terminal is a nine-acre prefabricated mass timber roof spanning the facility. The structure is engineered for high seismic resilience, specifically designed to withstand a 9.0 magnitude earthquake originating from the Cascadia Subduction Zone.

The terminal also establishes new environmental benchmarks for aviation infrastructure. The design incorporates an all-electric ground-source heat pump system, which the architects state will achieve a 50 percent reduction in energy use per square foot compared to previous operations.

Phase two enhancements and passenger experience

Following the opening of the project’s first phase in 2024, the newly completed second phase introduces a redesigned arrival sequence. The layout features new exit lanes on the north and south ends of the terminal to streamline connections between concourses. Additional upgrades include a new descent path to the baggage claim area, expanded post-security gathering spaces, skylit all-user restrooms, and an updated selection of local retail and dining options.

Port of Portland Executive Director Curtis Robinhold highlighted the regional focus of the construction effort and the materials utilized throughout the terminal.

“Thousands of local workers brought our shared vision to life, using locally sourced materials and setting a new bar for how it should be done,” Robinhold said. “I couldn’t be prouder of this special place we built together.”

Sharron van der Meulen, managing partner at ZGF Architects, noted that the terminal is designed to adapt to future aviation demands while serving as a gateway to the Pacific Northwest.

Industry recognition and operational impact

Since the initial phase debuted in 2024, the PDX terminal design has garnered multiple international accolades. These include the Prix Versailles World’s Most Beautiful Airport award, Fast Company’s Best Design in North-America distinction, and recognition from the Holcim Foundation for Sustainable Construction.

AirPro News analysis

We view the completion of the PDX terminal as a significant case study for mid-sized and large hub airports facing capacity constraints. Executing a $2 billion, one million-square-foot expansion while maintaining uninterrupted flight operations demonstrates a highly coordinated phasing strategy. The integration of a mass timber roof and an all-electric heat pump system aligns with the broader aviation industry’s push toward decarbonizing ground infrastructure, providing a viable template for future terminal modernization projects across North America.

Sources: ZGF Architects LLP via PR Newswire

Photo Credit: ZGF Architects LLP

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