Aircraft Refurbishing Market Analysis & Forecast: 2025-2032

Aircraft Refurbishing Market Analysis & Forecast: 2025-2032

Aircraft Refurbishing Market size is estimated to be valued at USD 585 Mn in 2025 and is expected to reach USD 839.8 Mn in 2032, exhibiting a compound annual growth rate (CAGR) of 5.3% from 2025 to 2032.

Key Takeaways

• By Aircraft Type, Narrow Body Aircraft is expected to dominate the global aircraft refurbishing market with a 53.5% share in 2025, driven by their extensive use in short to medium-haul operations and growing demand for cost-effective cabin upgrades.
• By Region, North America is projected to lead the global aircraft refurbishing market outlook with a 34.2% share in 2025, attributed to the region’s mature aviation infrastructure, high frequency of fleet renewals, and strong presence of MRO and refurbishment service providers.

Market Overview:

The Aircraft Refurbishing Market forecast is experiencing robust growth, driven by airlines’ needs to stretch fleet life due newer aircraft availability and steep inflating prices. Airlines can effectively refurbish cabins instead of making new purchases by updating in-flight entertainment systems, seating, and adding advanced connectivity- unlocking further customization options. Moreover, the spike in demand for VIP and corporate aviation has resulted in higher standard customization of cabin interiors to luxury levels. Lightweight materials and 3D printing technology are streamlining refurbishment processes, while eco-friendly materials in sustainable design fostered the greener construction movement.

Current Events and Its Impact on the Aircraft Refurbishing Market

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Pricing Analysis

The aircraft refurbishing market value offers diverse services with pricing varying by project complexity and region.

• The upgrades to the cabin interiors are extremely diverse: premium seats range from $50,000 to $300,000 each, economy seats from $5,000 to $15,000, LED lights go from $200,000 to $800,000 per aircraft, and In-flight entertainment systems start with basic WiFi for $500,000 and go up to $5 million for advanced 4K streaming.
• Structural adjustments include repainting which cost ($150,000–$600,000), composite repairs of ($1,000 – $5,000 per sq ft), and cargo conversions ($5 million – $15 million).
• Expenses related to system upgrades include flight deck modernization costing $2 million – $10 million, health monitoring devices $500,000 - $1.5 million, and SATCOM between $1 million and $3 million.
• North America has the highest AVC at 15-25% for FAA compliance and labour cost, Europe 10-20% due to environmental fees, Middle East varying ±10%, and Asia-Pacific is the lowest 15-20% due to subsidized labour.
• Extra services like 3D cabin scanning are available for $50,000-200,000, sustainability retrofits for $2,000-$6 million, and blockchain documentation for $100-500 per event. PDT goes from $10,000-50,000 daily, and certification costs are an additional 15-25% of project costs.
• Refurbishment is budgeted under $2 million whereas luxurious upgrades can be over $30 million. Pricing dependant on aircraft usage are becoming more prevalent among narrow-body operators.

Role of Artificial Intelligence (AI)

AI is transforming the aircraft refurbishing market demand by boosting efficiency, accuracy, and cost savings across refurbishment workflows. Maintenance and repair providers are leveraging AI-powered tools to streamline inspections, repairs, and project management.

For example, AI-driven drones rapidly inspect aircraft surfaces, capturing high-resolution images that AI algorithms analyze to detect corrosion, cracks, and wear—cutting inspection times by up to 70%.

Some of the important AI applications are shown below:

• Flaw identification: Computer vision is able to identify minute imperfections in the upholstery, flooring, and equipment to guarantee repairs are up to the required safety and aesthetic standards.
• Inventory optimization: AI improves efficiency by forecasting demand for refurbishment materials to reduce overstock and inventory costs (up to 20-30%).
• Some MRO providers deploy generative AI copilots for report generation, order placement, and scheduling which allows technicians to focus on more practical activities. This has resulted in a reduction of aircraft downtime by 40% and an increase in on-time project completion by 15%.

AI-humans collaboration is allowing refurbishing industries to have improved operational agility, reduced costs, increased safety, and quicker aircraft turnaround times.

Segmental Analysis

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Global Aircraft Refurbishing Market Insights, By Aircraft Type

In terms of aircraft type, narrow body aircraft are expected to dominate the aircraft refurbishing market growth, accounting for approximately 53.5% share in 2025. This dominance is attributed to the widespread use of narrow body aircraft in short- and medium-haul routes, which leads to higher demand for refurbishment and cabin upgrades to extend service life and enhance passenger experience.

The preference for refurbishing narrow body fleets continues to drive market growth as airlines focus on cost-effective ways to maintain operational efficiency and comply with evolving regulatory standards.

Regional Insights

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North America Aircraft Refurbishing Market Analysis and Trends

North America dominated the global aircraft refurbishing market in 2025, accounting for a significant 34.2% share in terms of value. This leadership is driven by the region’s advanced aviation infrastructure, stringent regulatory standards for aircraft maintenance and refurbishment, and the presence of major airline operators focused on fleet modernization. Growing emphasis on sustainability and fuel efficiency is also encouraging airlines to refurbish existing aircraft to extend service life and improve passenger comfort.

Europe Aircraft Refurbishing Market Analysis and Trends

Europe holds a strong position in the global aircraft refurbishing market, supported by a well-established network of airlines and MRO (maintenance, repair, and overhaul) providers across countries such as Germany, France, and the U.K. The region’s market growth is propelled by strict environmental and safety regulations imposed by the European Union Aviation Safety Agency (EASA), encouraging refurbishment activities that improve fuel efficiency and reduce emissions.

Additionally, Europe’s mature aviation sector is increasingly investing in cabin modernization and digital refurbishment solutions to enhance passenger experience and maintain competitiveness in the global market.

Dominating Countries in the Global Aircraft Refurbishing Market

United States Aircraft Refurbishing Market Analysis and Trends

The U.S. leads the North American aircraft refurbishing market, supported by its well-established regulatory framework and large commercial airline industry. Investments in fleet modernization and refurbishment programs, combined with stringent safety standards enforced by the FAA, continue to propel market growth. Furthermore, ongoing innovation in cabin design and materials is helping airlines meet evolving passenger expectations and environmental goals.

Germany Aircraft Refurbishing Market Analysis and Trends

Germany leads the European aircraft refurbishing market, driven by its strong industrial base and home to several prominent MRO providers. The country benefits from extensive investments in aerospace manufacturing and refurbishment technologies, supported by government initiatives aimed at fostering innovation and sustainability in aviation. Germany’s strategic location and robust logistics network also facilitate efficient refurbishment services for both domestic and international airlines, contributing to its dominant market position.

Market Report Scope

Global Aircraft Refurbishing Market- Drivers

• Growing appeal of premium economy class

Premium economy class has been popular among travelers as it offers significant upgrade over regular economy class without high price of business class fare. Premium economy class is preferred by passengers as it offers more space and comfort, premium meals with complementary bar service, and priority check-in and baggage delivery at the airport. For instance, Qatar Airways, a renowned airline based in Qatar, offers a premium economy class on select long-haul routes.

From 2020 onwards, they started introducing their new premium economy cabin, which provides passengers with additional space and comfort compared to regular economy class. Thus, it is expected to drive the market growth in the near future. Furthermore, major airlines around the world are introducing premium class section in their aircrafts for their customers. This, in turn, is expected to offer lucrative opportunities for refurbishment service providers to increase number of premium economy class seats for travelers.

• Increasing demand for VIP refurbishment of aircrafts

Asia Pacific, followed by North America is home to the largest population of high-net-worth individuals. This has supported growth of aerospace aftermarket albeit it is niche. Significant growth of this make has increased the demand for refurbishment and completion of cabin interiors of business and corporate jets.

Moreover, VIP refurbishment is one of the most profitable businesses as the price for complete services including manufacturing, engineering, interior design, installation, and certification of custom interiors comes out to be really high. VIP cabins are comprised of lounge area, bedroom, first-class seats, and dining room. This, in turn, is expected to boost the market growth over the forecast period.

Global Aircraft Refurbishing Market- Opportunities

• High growth in conversion into freighter from passenger aircrafts

Companies that are in cargo shipping business are looking for refurbished passenger aircrafts as they cost around one-third of a freighter aircraft. A P2F conversion extends the aircraft’s lifespan. Through this conversion, the companies transition airplanes into freighters, expanding economic life of the airplane after the useful operational service. Furthermore, any type of passenger plane can be converted into freighter, which extends its scope of this segment of the global aircraft refurbishing market.

• Development of advanced technologies

In-flight entertainment system components are integrated and repackaged consumer electronics. As these electronic components have small lifespan, aircraft refurbishing becomes extremely essential, in order to stay ahead and avoid obsolescence. Moreover, these technologies get outdated very quickly, key players have the opportunity to design, manufacture, and install customized inflight entertainment system and keep pace with new technological innovations. This, in turn, is expected to pose conducive business opportunities for market players in the near future.

Global Aircraft Refurbishing Market-Trends

• Endorsement of brand name

Over the years, aircraft cabins have transformed a lot in terms of features, functions, and applications. Airlines use cabins as presentation of their brand image and gain significance in the market by providing competitive features, services, ambiance, and comfort. The cabin designers are using lighting as a tool for branding as lighting has immense impact on space perception and create right ambience. Many airlines are inclined toward inclusion of LED lighting, larger windows, and overhead lockers, in order to enhance their brand identity.

• Emergence of 3D printed parts

3D printing technique has been incorporated widely in different industries as it is easy to produce and carries less weight. The lighter material from 3D printing results in less jet fuel consumption and eventually reducing air pollution. Moreover, it allows airlines to design more complex parts according to the demand and manufacturing of discontinued parts.

For instance, Airbus has been utilizing 3D technology for various purposes in the aircraft industry, including cabin refurbishment. While I don't have specific information about the exact timing of their implementation, Airbus has been actively incorporating 3D design and visualization tools into their processes for several years.

Global Aircraft Refurbishing Market: Key Developments

1. In 15^th Feb 2025, Air India, an air carrier company placed a record-breaking order for 470 aircraft and pledged significant expenditures for IT upgrades and aircraft refurbishment
2. In 13^th Feb 2023, Russia’s Federal Air Transport Agency (FAVT), also known as Rosaviatsiya, has approved the Dubai, United Arab Emirates (UAE)-based Global Jet Technic to maintain Russian-registered Airbus and Boeing aircraft.
3. In 2022, Lufthansa Technik, a company which provides worldwide maintenance, repair, and overhaul services for aircraft, engines, and components is currently carrying out the world's first Performance Restoration Shop Visit (PRSV) of a LEAP-1A engine. The PRSV serves to restore the performance of the engine.
4. In 2020, Airbus also announced plans to develop zero-emission hydrogen-powered aircraft by 2035, demonstrating their commitment to sustainability and environmental responsibility.

Analyst Viewpoint

• The Aircraft Refurbishing Market is poised for robust growth as airlines seek cost-effective alternatives to new aircraft purchases, focusing on extending the operational life of existing fleets.
• Rising emphasis on enhancing passenger experience through upgraded interiors, modern seating, advanced lighting, and in-flight entertainment is a key driver shaping refurbishment strategies.
• High upfront refurbishment costs and the limited availability of skilled labor remain significant restraints, particularly for smaller operators and emerging market players.
• The COVID-19 pandemic's lingering impact continues to affect airline budgets and refurbishment schedules, although a gradual recovery is underway.
• Asia-Pacific, led by China and India, is expected to be the fastest-growing region, fueled by expanding aviation infrastructure and rising demand for domestic and regional air travel.
• Emerging technologies such as 3D printing, smart cabin systems, and lightweight advanced materials are unlocking new efficiencies in design, customization, and turnaround times for refurbishment projects.

  Global Aircraft Refurbishing Market: Key Companies Insights

Key companies operating in the global aircraft refurbishing market are B/E Aerospace, Inc., Diehl Stiftung & Co. KG, Gulfstream Aerospace, Ltd, Hong Kong Aircraft Engineering Company Limited, JAMCO America, Jet Aviation AG, Lufthansa Technik AG, Sabreliner Aviation LLC, Safran SA, SCI Cabin Interiors, SIA Engineering Co Ltd., United Technologies Corporation, and Zodiac Aerospace S.A.

Sources:

Primary Research Interviews:

• Aircraft refurbishing service providers
• Airlines and aircraft operators
• Aircraft manufacturers
• Industry experts
• Others

Databases:

• Federal Aviation Administration (FAA) Database
• International Air Transport Association (IATA) Database
• Others

Magazines:

• Aviation Week & Space Technology
• Aircraft Interiors International
• MRO Management
• Others

Journals:

• Journal of Air Transport Management
• International Journal of Aviation, Aeronautics, and Aerospace
• Journal of Aircraft
• Others

Newspapers:

• The Wall Street Journal
• Financial Times
• The New York Times
• Others

Associations:

• Aircraft Fleet Recycling Association (AFRA)
• International Air Transport Association (IATA)
• Aircraft Interiors Association (AIA)
• Others

Public Domain Sources:

• National Transportation Safety Board (NTSB) Reports
• Federal Aviation Administration (FAA) Reports
• European Union Aviation Safety Agency (EASA) Reports
• Others

Proprietary Elements:

• CMI Data Analytics Tool
• Proprietary CMI Existing Repository of information for last 8 years

*Definition: Aircraft refurbishing refers to the process of renovating, updating, and enhancing the interior and/or exterior components of an aircraft to improve its appearance, functionality, and passenger experience. It involves a range of activities such as replacing or reupholstering seats, upgrading cabin lighting systems, modernizing lavatories, refreshing the cabin décor, installing new in-flight entertainment systems, and making necessary repairs or modifications.