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2026 Aviation Aftermarket Faces Supply Chain and Aging Fleet Challenges

Locatory.com reports high demand for legacy aircraft parts amid OEM delays and aging fleets, with shortages in basic fasteners impacting maintenance.

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This article is based on an official press release and market report from Locatory.com.

The global aviation aftermarket in 2026 continues to navigate a complex landscape defined by structural supply chain constraints, aging fleets, and delayed deliveries of next-generation aircraft. As airlines are forced to extend the lifecycles of their existing fleets, the demand for aftermarket parts has surged to unprecedented levels, placing immense pressure on maintenance providers and procurement teams.

A recent market overview published by Locatory.com on March 6, 2026, analyzes marketplace search data from February 2026 to highlight critical trends in aircraft parts availability. The data reveals sustained demand for legacy narrow-body engine components, high search volumes for Auxiliary Power Units (APUs), and a paradoxical shortage of basic structural hardware. By synthesizing this data with broader macroeconomic indicators, a clear picture emerges of an industry adapting to prolonged supply chain stress.

The Macroeconomic Drivers of Aftermarket Demand

OEMs Delays and Aging Fleets

To contextualize the Locatory.com data, it is essential to understand the macroeconomic factors driving the current demand for aircraft parts. The inability of major Original Equipment Manufacturers (OEMs) to meet delivery targets has created a severe bottleneck across the aviation sector. According to a late-2025 report by the International Air Transport Association (IATA) cited in the market research, delivery shortfalls of new aircraft reached at least 5,300 units. Furthermore, the industry order backlog surpassed 17,000 aircraft, which equates to nearly 12 years of current production capacity.

Because of these delayed entries into service for next-generation aircraft, particularly those powered by LEAP and Pratt & Whitney engines, airlines are keeping older planes flying longer. The IATA data indicates that the average global fleet age has risen to 15.1 years. This aging profile requires more frequent and extensive maintenance, adding an estimated $3.1 billion in additional maintenance costs for the industry and heavily straining Maintenance, Repair, and Overhaul (MRO) providers.

Locatory.com February 2026 Market Data Insights

Legacy Engines and Complex Systems

Locatory.com’s analysis of its “Top 50 most-searched” and “Top 50 hardest-to-find” parts provides a real-time snapshot of supply chain pressure points. Search activity is heavily concentrated on propulsion systems for legacy narrow-body aircraft, specifically the CFM56 engine family. The company recorded high demand for critical rotating components, such as High-Pressure Compressor Stage 1-2 spools and HPT disks, alongside fuel system components and starter assemblies. This confirms that legacy fleets will remain in service longer, requiring ongoing, heavy maintenance investments.

Additionally, APUs saw significant search activity. The Locatory.com report highlights the importance of APU reliability during ground cycles, particularly in winter operations where preheating and electrical loads exacerbate wear. Electrical power systems, including integrated drive generators and hydraulic pumps, as well as avionics like weather radar components, were also heavily sought after by procurement teams.

The Fastener Shortage Paradox

While demand is concentrated on complex systems, the list of the hardest-to-source parts reveals a different structural bottleneck. Supply chain constraints are not limited to high-value rotables or advanced avionics.

According to the Locatory.com market data, many of the most difficult items to procure are basic structural fasteners and hardware items, such as AN and NAS series fasteners.

This creates a paradox where multi-million dollar commercial aircraft face potential groundings due to severe shortages of basic screws and washers. Complex systems supporting regional aircraft, such as Embraer E-Jet FADECs and fuel modules, also appeared frequently on the shortage list, proving that regional operations face similar constraints to large commercial fleets.

Strategic Shifts in Procurement

Used Serviceable Material (USM) and Digitalization

With new OEM parts facing long lead times and high costs, the secondary market has become a central strategy rather than a fallback. The Used Serviceable Material (USM) market, comprising parts harvested from retired aircraft, inspected, and certified for reuse, is experiencing robust growth. Industry trends show USM is now viewed as a critical lever for operational reliability, sustainability, and cash preservation.

The complexity of sourcing parts has also led to an increased reliance on digital marketplaces and data analytics. In early 2025, Locatory.com launched transformative features providing unlimited access to detailed price histories and reference data. These tools empower procurement teams to bypass obscure databases and make smarter, faster, data-driven decisions.

AirPro News analysis

We observe that the current aviation supply chain is experiencing a “David and Goliath” scenario. The fact that basic structural fasteners are among the hardest parts to find underscores the extreme fragility of the aerospace ecosystem. The ripple effect of OEM delays is directly fueling this aftermarket boom. As airlines spend billions more on maintenance to keep older planes airworthy, real-time visibility into parts demand and pricing history has transitioned from a luxury to an operational necessity. MROs and airlines that fail to adopt digital procurement strategies and USM integration will likely face increased AOG (Aircraft on Ground) situations in the coming years.

Frequently Asked Questions (FAQ)

What is driving the high demand for aircraft parts in 2026?

The primary drivers are severe delivery delays from major aircraft manufacturers and an aging global fleet. With a backlog of over 17,000 new aircraft, airlines are forced to fly older planes longer, which requires more frequent and costly maintenance.

Which aircraft parts are currently the hardest to find?

According to Locatory.com’s February 2026 data, there is a paradoxical shortage of basic structural hardware, such as AN and NAS series fasteners. Additionally, complex systems for regional aircraft, like Embraer E-Jet FADECs and fuel modules, are highly constrained.

What is Used Serviceable Material (USM)?

USM refers to aircraft parts that have been harvested from retired or dismantled aircraft, rigorously inspected, and certified for reuse. It has become a vital sourcing strategy to bypass long OEM lead times and reduce maintenance costs.

Sources: Locatory.com

Photo Credit: Locatory

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MRO & Manufacturing

Honeywell Aerospace Orders Odysight.ai APU Visual Monitoring POC

Honeywell Aerospace and Odysight.ai launch a proof-of-concept for AI visual monitoring on APUs across 10,000+ aircraft.

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Odysight.ai has secured a purchase order from Honeywell Aerospace to launch a proof-of-concept for an advanced visual monitoring system designed to enhance predictive maintenance on auxiliary power units.

Announced in a press release on June 18, 2026, the collaboration will evaluate the integration of Odysight.ai’s miniature visual sensors and edge AI analytics within Honeywell Auxiliary Power Units (APUs). The initiative targets the early detection of internal wear and damage, aiming to reduce unplanned downtime across a global installed base of more than 10,000 APUs in commercial and defense fleets.

Visual sensing technology in hard-to-reach areas

The proof-of-concept focuses on deploying ruggedized, miniature cameras in highly inaccessible sections of the APU, such as the air intake. These sensors are designed to provide continuous, real-time internal monitoring between scheduled maintenance intervals.

By capturing visual data from inside the operating unit, the system allows maintenance crews to identify foreign object damage, structural wear, corrosion, and partial flow restrictions before they escalate into critical failures. Odysight.ai Chief Executive Officer Yehu Ofer described the collaboration as an important step for the company.

“With APUs installed across nearly the entire global defense and commercial aircraft fleet, a successful proof of concept could open a compelling pathway to scale across one of the industry’s largest installed bases,” Ofer stated. “We see this as a potential starting point for broader integration opportunities across Honeywell Aerospace aviation portfolio.”

Expanding predictive maintenance footprint

The Honeywell agreement follows a series of recent expansions for Odysight.ai in the aerospace and defense sectors. In January 2026, the Israel-based company received two pilot orders from a major defense customer to monitor aerial platforms, including an operational combat helicopter.

In April 2026, Odysight.ai signed a commercial collaboration agreement with GACI Technologies to introduce its predictive maintenance solutions to the French aerospace market. Concurrently, Honeywell Aerospace has been advancing its own digital maintenance capabilities. Also in April 2026, maintenance provider Revima signed a five-year agreement with Air Astana Group to service Honeywell 131-9A APUs, incorporating digital predictive maintenance tools to optimize lifecycle costs.

AirPro News analysis

We view the integration of visual edge artificial intelligence into APU maintenance as a logical progression in the industry’s shift toward condition-based monitoring. Traditional predictive maintenance relies heavily on vibration, temperature, and pressure sensors, which often detect anomalies only after physical degradation has begun.

By introducing direct visual confirmation into the diagnostic loop, operators can potentially bridge the gap between sensor alerts and physical borescope inspections. If the proof-of-concept proves successful in the harsh operating environment of an APU, it could validate the broader use of embedded visual sensors across other critical aircraft systems, reducing the reliance on routine, labor-intensive teardowns.

Sources: Odysight.ai Inc. via GlobeNewswire

Photo Credit: Odysight.ai Inc.

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MRO & Manufacturing

GE Aerospace Reports $210B Backlog on Spare Parts Surge

GE Aerospace Q2 2026 update: $210B backlog, 40% spare parts order surge, defense milestones, and hybrid electric engine progress.

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GE Aerospace reported a total company backlog exceeding $210 billion, driven by a 40 percent year-over-year surge in spare parts orders between early March and mid-May 2026.

In a second-quarter investor update published on June 8, 2026, the manufacturer detailed strong commercial aftermarket demand and outlined recent milestones across its military and advanced technology portfolios. The update followed recent executive appearances, including a May 27, 2026, presentation at the Bernstein Strategic Decisions Conference and a June 7, 2026, interview with Chairman and CEO Larry Culp at the International Air Transport Association (IATA) conference in Rio de Janeiro, Brazil.

Commercial aftermarket demand drives backlog

Commercial services now account for over $170 billion of the company’s total backlog. GE Aerospace reported a 30 percent increase in Commercial Engines and Services (CES) internal shop visit (ISV) revenue over the past 12 months. Spare parts revenue grew by more than 25 percent during the same period.

The manufacturer highlighted the longevity of its CFM56 engine program, noting the average fleet age remains under 15 years. The company projects that 80 percent of CFM56 shop visits over the next few years will come from engines under 20 years old. For newer generation powerplants, GE Aerospace expects the LEAP engine installed base to more than double between 2025 and 2030. In the widebody sector, the GEnx engine program maintains a life-of-program win rate exceeding 75 percent.

“These are encouraging indicators that underlying services demand remains robust. We are confident in our outlook and remain on track to deliver the high end of our full-year guidance.”

The company is scheduled to host its second-quarter earnings call on July 16, 2026, where it will provide further financial details.

Defense portfolio and advanced propulsion milestones

GE Aerospace currently powers two-thirds of United States military combat and rotorcraft fleets. The company hosted a Defense & Propulsion Technologies showcase at its Lynn, Massachusetts facility, where it reported a 30 percent engine output increase in 2025 achieved without additional headcount. The manufacturer projects that advanced defense programs will account for 25 percent of its defense revenue by 2035.

The investor update detailed several advancements in military propulsion programs. GE Aerospace completed the Assembly Readiness Review for the XA102 adaptive cycle engine, advancing the U.S. advanced combat propulsion program to prototype development. In the Collaborative Combat Aircraft (CCA) sector, the U.S. Air Force awarded the company a contract to complete a Preliminary Design Review (PDR) for a medium thrust CCA utilizing the GE426 engine. Concurrently, the GEK1500 engine, developed in partnership with Kratos Defense & Security Solutions for a lower thrust CCA, was selected to move to the PDR phase.

Next-generation technology and AI integration

The company reported progress on several experimental and next-generation propulsion initiatives. GE Aerospace demonstrated a generative artificial intelligence application capable of producing a preliminary hypersonic ramjet engine design in seconds, a development intended to compress early design work timelines.

In the electric and hybrid propulsion sector, the manufacturer partnered with BETA Technologies to develop a turbogenerator for the MV250 autonomous military logistics vertical takeoff and landing (VTOL) aircraft. GE Aerospace also completed the first ground test of a megawatt-class hybrid electric engine as part of the National Aeronautics and Space Administration (NASA) Electrified Powertrain Flight Demonstration (EPFD) project.

AirPro News analysis

We note that the 40 percent spike in spare parts orders reflects broader commercial aviation industry constraints. With new aircraft deliveries delayed across the manufacturing sector, operators are investing heavily to keep existing, older fleets operational. The CFM56 data provided by GE Aerospace illustrates this dynamic clearly, as airlines commit to major shop visits for engines that might otherwise have faced retirement in a more fluid delivery environment.

On the defense side, the rapid progression of the GE426 and GEK1500 engines through the Preliminary Design Review phase underscores the U.S. Air Force’s prioritization of the Collaborative Combat Aircraft program. The integration of generative AI into hypersonic ramjet design suggests manufacturers are aggressively seeking ways to shorten the traditional, decades-long military engine development cycle to meet emerging defense requirements.

Sources: GE Aerospace

Photo Credit: GE Aerospace

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MRO & Manufacturing

American Airlines Tulsa Maintenance Base Turns 80

American Airlines marks 80 years of its Tulsa MRO base, now the world’s largest commercial aircraft maintenance facility.

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On June 18, 2026, American Airlines (AA) marked the 80th anniversary of its Tech Ops – Tulsa maintenance facility at Tulsa International Airport (TUL), celebrating a site that has grown from a post-war surplus plant into the largest commercial aircraft maintenance base in the world.

In a press release issued to commemorate the milestone, the carrier highlighted the facility’s evolution and its role as the backbone of the airline’s technical operations. The 260-acre complex currently employs nearly 5,000 team members and continues to expand following a series of recent capital investments and workforce additions aimed at supporting the airline’s Boeing 737 and Boeing 787 fleets.

Historical growth and operational scale

The origins of the Tulsa base date back to 1945 when the United States government listed a military aircraft plant as surplus property. American Airlines negotiated a lease with the City of Tulsa and officially opened the maintenance base in 1946, relocating its maintenance and engineering operations from LaGuardia Airport (LGA) in New York.

Today, the property spans more than 260 acres and is anchored by four of the original hangars, which remain in active use. The facility handles a significant portion of the airline’s heavy maintenance, overhaul, and repair work.

Kevin Brickner, Senior Vice President of Technical Operations for American Airlines, praised the workforce in the anniversary announcement, noting that the facility remains a cornerstone of the airline’s aircraft maintenance operation.

“Our team of skilled aviation maintenance professionals in Tulsa and across our system is the best in the business, and they set the standard for safety, quality and ingenuity. We wouldn’t be where we are today without our team members, the City of Tulsa and the State of Oklahoma.”

Recent capital investments and fleet support

The 80th anniversary follows a period of sustained financial investment in the Tulsa infrastructure. In May 2025, the Tulsa Municipal Airport Trust issued a $400 million special facility revenue bond offering, guaranteed by American Airlines Group, to finance major improvements to the overhaul and maintenance base. This funding built upon a December 2023 award of $22 million from the State of Oklahoma’s Business Expansion Incentive Program, which was directed toward an ongoing $350 million improvement project.

These capital improvements have been accompanied by workforce expansion to support specific aircraft types. In September 2024, the airline added 227 aircraft maintenance technicians and more than 100 support staff to the Tulsa base. This personnel increase was designed to establish an additional Boeing 737 overhaul line and facilitate the return of a Boeing 787 heavy maintenance check line to the facility.

To maintain a pipeline of skilled technicians, American Airlines formalized a partnership with Tulsa Tech in 2024. The agreement provides interview opportunities for top students and included the airline’s sponsorship of the school’s adult student team at the 2026 Aerospace Maintenance Council Competition.

AirPro News analysis

The sustained investment in Tech Ops – Tulsa highlights a broader industry trend where major carriers are consolidating heavy maintenance capabilities at established, centralized hubs rather than fragmenting the work across smaller regional stations. By securing municipal bonds and state grants, American Airlines has effectively leveraged public-private partnerships to modernize an 80-year-old footprint without bearing the entire capital expenditure upfront.

Furthermore, bringing a Boeing 787 heavy maintenance check line back to Tulsa indicates a strategic preference for keeping complex, widebody maintenance in-house where the airline has direct oversight of quality control and turnaround times. As the global supply chain for aircraft parts and maintenance, repair, and overhaul (MRO) services remains constrained, maintaining the world’s largest internal commercial aircraft maintenance base provides American Airlines with a distinct operational buffer against external delays.

Sources: American Airlines

Photo Credit: American Airlines

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