Aircraft Maintenance, Repair, and Overhaul (MRO) is a critical aspect of the aviation industry. It is a comprehensive process that ensures the safety and airworthiness of aircraft. In recent years, MRO technologies have advanced significantly, providing operators with more efficient, cost-effective, and reliable solutions.

Some of the latest advancements include 3D printing technology, artificial intelligence for data analysis, and robotics—which can be used to perform maintenance on parts of an aircraft that are hard to reach. Blockchain technology is also utilized for building more secure, transparent supply chains for aircraft parts and components. It reduces the risk of incorporating faulty components in maintenance and repairs.

There are multiple companies at the forefront of developing advanced technologies for aircraft MRO—Boeing, Airbus, GE Aviation, Honeywell Aerospace, Lufthansa Technik, Rolls-Royce, and Pratt & Whitney are just a few examples.

Predictive Maintenance

Predictive maintenance technologies use sensors, data analytics, and machine learning to predict maintenance needs before failures occur. They collect data on aircraft systems, components, and structures and analyze it to detect abnormalities or potential issues. These technologies can also use real-time data to adjust maintenance schedules based on aircraft usage, which reduces maintenance downtime and costs.

Some of the key benefits of predictive maintenance technologies include early detection of potential issues before they become critical failures; increased aircraft availability and utilization; and improved safety and reliability.

Boeing’s Insight Accelerator offers users a cloud-based solution for predictive maintenance as part of its Flight Data Analytics suite. Custom alerts enable proactive measuring of part failures. The Insight Accelerator helps to maximize the useful service life of aircraft.

According to Boeing, the Insight Accelerator “eliminates the need for specialized data science or programming skills.” This solution “delivers machine learning algorithms that help identify probable trends and critical issues at a granular level.”

Honeywell Aerospace has developed a “prescriptive” maintenance solution as an alternative for airline maintenance. It is called Honeywell Forge for Airlines and is designed to eliminate most unscheduled events by preventing issues from happening. The approach utilizes advanced predictive analytics to offer prescribed actions for maintenance. Honeywell Forge also takes advantage of cognitive diagnostics and connected airplane technologies.

Josh Melin, Product Line Director, found that “airlines using Honeywell Forge Connected Maintenance for APUs have experienced a 30–50% reduction in operational disruptions caused by the APU and a 10–15% reduction in costly premature removals,” according to an article published by Honeywell. “The no-fault-found rate has been reduced to 1.5 % and the service has achieved 99% predictive accuracy.”

Augmented Reality (AR)

AR technologies use computer-generated sensory input, such as sound, video, graphics, and GPS data, to enhance real-world experiences. In MRO, AR technologies can provide maintenance technicians with real-time data and instructions, improving their efficiency and accuracy. AR technologies can also provide remote support, allowing experts to guide technicians through complex repairs and inspections.

AR technologies help to increase maintenance efficiency and accuracy as well as improve safety and quality assurance.

The company VSight Remote uses augmented reality tech to enable maintenance technicians to collaborate in real-time and to provide and receive remote assistance.

Boeing Vancouver served as the lead on a project team to research the potential of using augmented reality for aircraft inspections and maintenance. This technology “will allow inspectors to precisely note and review defects on the surface of an airplane by comparing its current state with digital inspection records displayed on a handheld tablet,” according to Canada’s Digital Technology Supercluster.

Jack Hsu, Senior Manager at Boeing Vancouver, explained in a comment on the project that “AR tools can make time-consuming maintenance manual processes, such as aircraft inspections and repairs, much more efficient.”

Additive Manufacturing (AM)

Additive manufacturing, or AM, technologies—such as 3D printing—use digital designs to create complex and customized components. In MRO, AM technologies can produce parts on-demand, reducing lead times and inventory costs. AM technologies can also produce parts that are difficult or impossible to obtain through traditional manufacturing methods.

GE Aviation received its first FAA clearance to incorporate a 3D-printed component in a commercial jet engine in 2015. Because 3D-printed components can reduce the total number of parts required, AM technologies reduce potential failure modes because there is a reduced amount of joint welding.

Big Data Analytics

Big data analytics technologies use machine learning and artificial intelligence to analyze large amounts of data to identify patterns and trends. In MRO, big data analytics can analyze data from various sources, such as maintenance records, flight data, and weather forecasts, to optimize maintenance schedules and reduce downtime. These technologies can also identify areas for improvement in maintenance procedures and reduce costs.

In addition to additive manufacturing, GE Aviation utilizes big data analytics to provide more proactive maintenance recommendations. Pratt & Whitney also makes use of these methods to monitor the performance of new engines during flight.

A U.S. Air Force logistics team is building a Basing & Logistics Analytics Data Environment (BLADE) data system that is driven by artificial intelligence. By making data analytics faster and easier, maintenance can be scheduled more efficiently.

Aircraft MRO technologies are rapidly advancing, providing operators with more efficient, cost-effective, and reliable solutions. Predictive maintenance technologies can detect potential issues before they become critical failures, reducing maintenance downtime and costs. Augmented reality technologies can provide maintenance technicians with real-time data and instructions, improving their efficiency and accuracy. Additive manufacturing technologies can produce parts on-demand to reduce lead times and inventory costs. Big data analytics technologies can analyze large amounts of data to optimize maintenance schedules. With these technologies, the aviation industry can improve safety, reliability, and profitability.