Overview
- New analysis pegs the 2025 cost burden at more than $11 billion, including about $4.2 billion in extra fuel, $3.1 billion in additional maintenance, $2.6 billion in engine leasing and $1.4 billion in spare‑parts inventory.
- Researchers cite labor, materials and parts shortages, prolonged engine shop visits and intensifying competition from defense work for limited capacity as key drivers.
- A record backlog exceeding 17,000 aircraft in 2024 and lead times nearing seven years are keeping older, less efficient jets in service longer.
- Passenger demand rose 10.4% in 2024 versus 8.7% capacity growth, pushing load factors to roughly 83.5% and constraining carriers’ ability to add seats through 2025.
- The report urges wider access to alternative parts (PMA/USM), better end‑to‑end visibility, predictive maintenance and shared parts pools, along with expanded repair capacity and workforce investment, as IATA signals possible competition re‑examination in the aftermarket.