Aircraft Health Monitoring Systems Market Size and Share
Aircraft Health Monitoring Systems Market Analysis by Mordor Intelligence
The aircraft health monitoring systems market stood at USD 6.96 billion in 2025 and is projected to reach USD 9.60 billion by 2030, advancing at a 6.63% CAGR. The upward trajectory reflects airline, MRO, and OEM investments in data-driven maintenance that cut unscheduled ground time and improve fleet availability. Regulatory bodies have tightened flight-data and structural-integrity rules, accelerating the installation of onboard analytics and secure connectivity systems.[1]Source: Federal Aviation Administration, “Advisory Circular AC 120-82,” faa.gov OEM digital platforms such as Airbus Skywise and Boeing Airplane Health Management scaled rapidly, providing real-time diagnostics across mixed fleets. Asia-Pacific fleet growth and urban-air-mobility prototypes further widened the application scope, while cybersecurity gaps and retrofit costs tempered near-term adoption.
Key Report Takeaways
- By end user, airlines held 54.25% of the aircraft health monitoring systems market share in 2024, while the MRO segment is forecast to expand at a 7.54% CAGR to 2030.
- By subsystem, aero-propulsion led with a 42.30% revenue share in 2024; aircraft structures are projected to grow at a 7.10% CAGR through 2030.
- By component, hardware accounted for 48.60% of the aircraft health monitoring systems market size in 2024, but software is set to post the fastest 8.45% CAGR between 2025 and 2030.
- By fit, line-fit represented 62.54% of the aircraft health monitoring systems market size in 2024, whereas retrofit installations will rise at a 7.90% CAGR to 2030.
- By transmission mode, on-board systems captured 55.90% market revenue in 2024, and ground-based transmission is anticipated to grow at 8.45% CAGR through 2030.
- By aircraft type, fixed-wing platforms held a 57.20% share in 2024; advanced air mobility is forecasted to witness a 10.54% CAGR up to 2030.
- By geography, North America dominated with a 40.6% share in 2024, while Asia-Pacific will likely register a 7.25% CAGR over the forecast period.
Global Aircraft Health Monitoring Systems Market Trends and Insights
Drivers Impact Analysis
Driver | (~) % Impact on CAGR Forecast | Geographic Relevance | Impact Timeline |
---|---|---|---|
Predictive maintenance imperative | +1.8% | Global | Medium term (2-4 years) |
Regulatory mandates for flight and FOQA data | +1.2% | North America and EU, expanding to APAC | Short term (≤ 2 years) |
Rapid commercial fleet expansion | +1.5% | APAC core, spill-over to MEA | Long term (≥ 4 years) |
Connected-aircraft and IoT ecosystem maturity | +1.0% | Global, led by North America and EU | Medium term (2-4 years) |
Digital-twin-driven virtual sensor modelling | +0.8% | Global, concentrated in advanced markets | Long term (≥ 4 years) |
On-board edge-AI avionics processors | +0.6% | Global, early adoption in premium segments | Long term (≥ 4 years) |
Source: Mordor Intelligence
Predictive Maintenance Imperative
Airlines reported notable cuts in unscheduled maintenance events after adopting data-driven prognostics, with Honeywell indicating 99% prediction accuracy that avoided premature part removals.[2]Source: Honeywell Aerospace, “Moving Beyond the Hype of Predictive Maintenance,” aerospace.honeywell.com Rising labor costs and higher engine shop-visit rates made predictive maintenance a strategic hedge against budget pressure, especially as new-generation jets produce terabytes of sensor data per flight. Therefore, the aircraft health monitoring systems market transitioned from optional analytics to core operational infrastructure, embedding algorithms that flag anomalies during scheduled turnarounds. Wider adoption also improved asset-utilization metrics valuable to lessors and financiers. Collectively, these factors underpin a strong, multi-year stimulus for investment across the aircraft health monitoring systems market.
Regulatory Mandates for Flight and FOQA Data
The FAA’s revised Flight Operational Quality Assurance circular compelled US operators to institute continuous data-monitoring programs. ICAO and EASA rules mirrored this stance, extending requirements to structural components and aging-aircraft safety. Operators above 20,000 kg MTOW must now archive and analyze large data sets, turning compliance into a guaranteed buyer pool for monitoring software and secure recorders. Protection measures that shield airlines from punitive misuse of FOQA findings fostered voluntary uptake, further enlarging the aircraft health monitoring systems market.
Rapid Commercial Fleet Expansion
Airbus forecasted that passenger demand in Asia-Pacific will climb 3.8% annually through 2043, necessitating thousands of new deliveries. Each new narrowbody or widebody enters service with embedded diagnostics, instantly enlarging the installed base for aftermarket analytics contracts. Simultaneously, carriers launched retrofit programs on legacy aircraft to harmonize fleet-wide maintenance standards, pushing incremental growth in the aircraft health monitoring systems market size. High-cycle regional jets and low-cost-carrier operations magnified the value of predictive insights, boosting uptake across both mature and emerging routes.
Connected-Aircraft and IoT Ecosystem Maturity
More than 12,000 commercial jets had been linked to the Skywise data backbone by early 2025, transmitting secure streams that enable continuous surveillance. Satellite bandwidth improvements and low-latency links allowed data offloading even on polar or oceanic sectors. Edge processors executed first-line anomaly detection on board, while cloud engines refined models using fleet-wide comparisons. This bidirectional data flow strengthened OEM, airline, and MRO collaboration, anchoring an integrated aircraft health monitoring systems market in which insights translate directly into dispatch-reliability gains and optimized parts inventory.
Restraints Impact Analysis
Restraint | (~) % Impact on CAGR Forecast | Geographic Relevance | Impact Timeline |
---|---|---|---|
Cyber-security and data-integrity risks | -1.4% | Global, acute in connected aircraft | Short term (≤ 2 years) |
High capex/retrofit integration cost | -1.1% | Global, pronounced in emerging markets | Medium term (2-4 years) |
Operator-lessor-OEM data-ownership disputes | -0.8% | Global, concentrated in commercial aviation | Medium term (2-4 years) |
Sensor ruggedization limits on ageing fleets | -0.6% | Global, acute in cost-sensitive markets | Long term (≥ 4 years) |
Source: Mordor Intelligence
Cyber-security and Data-Integrity Risks
A 2024 GAO review pinpointed unpatched avionics software and supply-chain weaknesses that could permit data manipulation.[3]Source: US Government Accountability Office, “Aviation Cybersecurity: FAA Should Fully Implement Key Practices,” gao.gov IBM recorded a 74% jump in aviation-sector cyber incidents since 2020. A compromised sensor may feed spurious parameters to ground crews, undermining trust in predictive dashboards and potentially grounding aircraft until verification. Regulators drafted cohesive rules, yet operators still face integration costs for encryption, network segmentation, and continuous-monitoring tools. These uncertainties have postponed some retrofit programs and curbed near-term expansion of the aircraft health monitoring systems market.
High Capex/Retrofit Integration Cost
Cranfield University research showed that a full monitoring suite can exceed USD 1 million per legacy aircraft once installation downtime and certification testing are included. Added weight from sensor wiring also raises fuel burn, eroding cost-saving claims on older fleets. Smaller airlines, therefore, stagger adoption or limit deployments to engines only. In price-sensitive regions, such financial hurdles limit penetration, slowing overall CAGR for the aircraft health monitoring systems market despite proven long-term benefits.
Segment Analysis
By End User: Airlines Maintain Scale, MROs Gain Momentum
Airlines held 54.25% of the aircraft health monitoring systems market in 2024, reflecting their direct accountability for dispatch reliability and passenger safety. Many flag carriers embedded OEM dashboards that flag anomalies hours before landing, allowing part pre-positioning and faster turnarounds. The aircraft health monitoring systems market size for airlines is expected to progress steadily as digital-first start-ups enter service with fully connected fleets. Independent maintenance, repair, and overhaul providers posted a brisk 7.54% CAGR outlook, using analytics dashboards to deliver value-added contracts that rival OEM packages. Their growth has been propelled by deals such as Lufthansa Technik’s AI-based inspection platform that cuts hangar time by 75%. Data-sharing protocols remain a sticking point because airlines aim to preserve proprietary flight-profile insights while MROs need access to refine predictive models. Consequently, partnerships that guarantee reciprocal access reshape procurement norms across the Aircraft Health Monitoring market.
In parallel, leasing companies demanded standardized data formats that support residual-value tracking, nudging airlines toward common interfaces. Low-cost carriers embraced non-proprietary software to sidestep vendor lock-in, stimulating open-architecture competition. The scale advantages of major network airlines continue to underpin bulk sensor-procurement agreements. Yet, regional players now tap cloud analytics on a subscription basis, widening entry pathways into the aircraft health monitoring systems market.
Note: Segment shares of all individual segments available upon report purchase
By Sub-system: Engines Lead, Structures Accelerate
Aero-propulsion systems generated 42.30% of global revenue in 2024, underscoring the centrality of engine condition monitoring to flight safety and cost. High-bypass turbofan maintenance bills justify sophisticated vibration and performance analytics, making engine OEMs early movers in the aircraft health monitoring systems industry. Aircraft structures, however, are projected to advance at a 7.10% CAGR as fiber-optic strain sensors and embedded Bragg gratings become lighter and cheaper. Airlines that operate composite-fuselage wide-bodies seek real-time insight into hidden delamination, elevating demand for structural-health dashboards.
The aircraft health monitoring systems market share of structural applications could widen further once regulators accept virtual inspection records in lieu of some manual checks. Digital twin platforms that overlay live strain data onto simulated load maps have shortened engineering-change cycles, opening new service revenues for OEMs. Meanwhile, avionics, environmental control, and auxiliary power units expanded monitoring to satisfy airframers’ performance-guarantee clauses. Market participants that blend multi-system analytics into a single cockpit view stand to capture incremental share within the aircraft health monitoring systems market.
By Component: Hardware Dominates, Software Captures Value
Hardware occupied 48.60% of revenue in 2024 through sensor packages, data gateways, and rugged recorders. Yet software is forecast to clock an 8.45% CAGR, becoming the principal margin driver as algorithms convert raw streams into actionable alerts. Line-fit installations increasingly ship with common-standard sensors, tilting incremental spending toward machine-learning licenses, cloud storage, and cross-fleet benchmarking dashboards. Two global carriers jointly piloted a neural-network tool that aggregated engine and airframe data, delivering 14% deeper fault-isolation accuracy and showcasing the monetization potential of software layers within the aircraft health monitoring systems market.
Services such as systems integration and regulatory documentation retained steady demand because operators require end-to-end solutions rather than standalone apps. Cyber-secure APIs, training modules, and data-quality audits grew in tandem, reinforcing a holistic value stack. Consequently, hardware vendors accelerated moves into analytics through acquisitions and joint ventures, illustrating how the competitive frontier of the aircraft health monitoring systems market is inexorably shifting toward software dominance.
By Fit: Line-fit Integrated, Retrofit Rising
Line-fit configurations accounted for 62.54% of the aircraft health monitoring systems market size in 2024, thanks to factory-level design synergies that minimize wiring and certification hurdles. OEMs embed monitoring nodes during assembly, allowing weight-neutral placement and enabling broader parameter capture. Airlines prefer such integrated kits because they avoid future service-bulletin costs. Though burdened by higher capex, retrofit programs are slated for a 7.90% CAGR as operators extend the life of 15-year-plus aircraft, especially freighters. Wireless sensors trimmed installation time by up to 40%, making partial retrofits economically viable.
Third-party providers developed portable ground receivers that tap standard quick-access recorder ports, which lowers engineering-order complexity. Leasing houses sponsor retrofit bundles tied to power-by-the-hour contracts, offsetting initial cost via predictable maintenance savings. This hybrid innovation cycle keeps the dynamic aircraft health monitoring systems market, drawing new players into approval and modification services while OEMs maintain an edge on future production orders.

Note: Segment shares of all individual segments available upon report purchase
By Transmission Mode: On-board Real Time, Ground-based Deep Analysis
On-board processing delivered 55.90% of revenue in 2024, reflecting airline preference for immediate crew alerts and dispatch decisions. Rudimentary diagnostic computers evolved into AI-enabled edge devices that could classify anomalies during climbs. Ground-based transmission, however, should expand at 8.45% CAGR because enhanced satellite links and 5G corridors allow full-flight data streaming. Cloud clusters can then execute computation-heavy digital-twin models without bandwidth constraints, adding depth to prognostic reports.
Hybrid architectures dominate bids, with non-critical data landing post-flight while safety-critical triggers remain on board. Regulators endorse this split approach as long as reliability analyses disclose latency risks. Vendors that bundle airtime, cybersecurity, and analytics under a single service level agreement capture sizeable contracts, reinforcing the structural sophistication of the aircraft health monitoring systems market.
By Aircraft Type: Fixed-Wing Core, Advanced Air Mobility Emergent
Fixed-wing fleets generated 57.20% of sales in 2024 across commercial, business, and defense niches. Each wide-body or single-aisle program integrates standardized engine, avionics, and structural sensors, sustaining the baseline scale of the aircraft health monitoring systems market. Rotary-wing platforms employed vibration-specific solutions to address gearbox fatigue, yet market share remained lower due to fleet size. Advanced air mobility vehicles are forecast to rise at a 10.54% CAGR as eVTOL developers bake in battery, propulsion, and structural monitoring from day one.
Certification roadmaps for urban air taxis demand 10-9 failure probabilities, effectively mandating continuous health data capture. Developers collaborate with semiconductor partners such as NXP to embed high-performance processors that safeguard latency budgets. Lessons learned in this environment could trickle back into conventional airframes, reinforcing innovation links across the aircraft health monitoring systems market.
Geography Analysis
North America remained the principal revenue center with 40.6% of the aircraft health monitoring systems market in 2024 as FAA mandates, mature MRO infrastructure, and early digital-service adoption converged. US carriers began replacing legacy quick-access recorders with 25-hour versions that align with new safety mandates, driving a steady upgrade cycle. Canadian operators similarly adopted engine-health kits for winter reliability, keeping regional demand resilient. The aircraft health monitoring systems market size within the region is forecast to retain mid-single-digit growth amid strict cyber-compliance requirements.
Asia-Pacific is projected to post the fastest 7.25% CAGR through 2030. Domestic networks in China, India, Indonesia, and Thailand moved from schedule recovery to optimization, relying on predictive dashboards to manage high-utilization narrow-body fleets. Airlines deploying new A320neo and B737-8 aircraft obtained factory-installed diagnostics, expanding the Aircraft Health Monitoring market. Governments promoted indigenous MRO capability, which leveraged cloud analytics to win third-party business, reinforcing regional self-sufficiency.
Europe delivered steady replacement demand amid EASA-driven safety-management-system reforms that compel structural-health assessments on aging airframes. Lufthansa Technik, Air France-KLM, and multiple low-cost carriers used monitoring data to refine parts pooling, improving profit resilience under carbon-pricing pressure. The region’s digital-twin research consortia attracted EU funding, enhancing analytic sophistication and ensuring that the aircraft health monitoring systems market remains a strategic component of broader aerospace innovation goals.

Competitive Landscape
The aircraft health monitoring systems market registered moderate consolidation, dominated by The Boeing Company, Airbus SE, Honeywell International Inc., GE Aerospace, and RTX Corporation. These five firms blended manufacturing scale with proprietary analytic ecosystems, capturing a large services backlog and shaping data standards. Boeing sought USD 50 billion in annual services by 2028, hinging on the market's growth. Airbus capitalized on Skywise alliances, while Honeywell packaged sensors, edge processors, and AI software into subscription bundles.
Specialist entrants focused on narrow niches such as embedded fiber sensors, edge-certificate cybersecurity, and battery prognostics. Lockheed Martin’s autonomous inspection drones demonstrated 99.59% defect recognition accuracy and won military trials. MTU’s acquisition of 3D.aero added machine-vision expertise that cuts borescope times.
Customer bargaining power increased as airlines demanded interoperable APIs and open data rights. Some carriers negotiated joint-intellectual-property clauses, aiming to in-source analytics portions over time. Suppliers responded by offering tiered licensing and white-label dashboards. The resulting competitive chessboard keeps pricing rational yet innovation brisk, positioning the aircraft health monitoring systems market for sustained evolution through strategic alliances and spin-offs such as Honeywell’s aerospace restructuring.
Aircraft Health Monitoring Systems Industry Leaders
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The Boeing Company
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Honeywell International Inc.
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RTX Corporation
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Safran SA
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General Electric Company
- *Disclaimer: Major Players sorted in no particular order

Recent Industry Developments
- May 2025: ACE Aeronautics selected Ultra PCS and Curtiss-Wright to provide the ED-112A Fortress HUMS CVR/FDR for UH-60L Black Hawk helicopters. Covering 13 aircraft, including a prototype, shipments will begin this year and run through 2028, delivering advanced monitoring solutions for foreign military rotorcraft platforms.
- March 2025: RTX’s Pratt & Whitney and Collins Aerospace joined JetZero’s blended-wing-body demonstrator to cut fuel burn by 50% and integrate advanced monitoring.
Global Aircraft Health Monitoring Systems Market Report Scope
Aircraft Health Monitoring System (AHMS) is a collection of strategies, tools, solutions, and approaches that are closely connected to a hardware and software system that performs remote monitoring of airplane data in order to understand its present or future serviceability and performance.
The Aircraft Health Monitoring Systems Market is segmented by end-user, subsystems, integrated vehicle health management systems, and geography. By end user, the market has been segmented by commercial and military. By subsystems, the market has been segmented by aero-propulsion, avionics, ancillary systems, and aircraft structures. By integrated vehicle health management systems, the market has been segmented into diagnostics, prognostics, condition-based maintenance, and adaptive control. By geography, the market has been segmented by North America, Europe, Asia-Pacific, Latin America, and the Middle East and Africa. Moreover, the report offers a market forecast and is represented by USD million. Furthermore, the report also includes various key statistics on the market status of leading market players and provides key trends and opportunities in the Middle East and Africa Inflight Entertainment and Connectivity Market.
By End User | OEMS | |||
Airlines | ||||
MRO | ||||
By Sub-system | Engines | |||
Avionics | ||||
Aircraft Structures | ||||
Environmental Control and Ancillary Systems | ||||
By Component | Hardware | Sensors | ||
Avionics | ||||
Flight Data Managemnet Systems | ||||
Connected Aircarft Solutions | ||||
Ground Services | ||||
Software | Onboard Software | |||
Diagnostics Analytics | ||||
Prognostics Analytics | ||||
Services | Integration and Customisation | |||
MRO/Condition-Monitoring Services | ||||
By Fit | Line-fit | |||
Retrofit | ||||
By Transmission Mode | Onboard | |||
Ground-based | ||||
By Aircraft Type | Fixed-Wing | Commercial Aviation | Narrowbody Aircraft | |
Widebody Aircraft | ||||
Regional Transport Aircraft | ||||
Military Aviation | Fighter Aircraft | |||
Transport Aircraft | ||||
Special Mission Aircraft | ||||
Business and General Aviation | Business Jets | |||
Light Aircraft | ||||
Rotary Wing | Commercial Helicopters | |||
Military Helicopters | ||||
Military Unmmaned Aerial Vehicles | ||||
Advanced Air Mobility | ||||
By Geography | North America | United States | ||
Canada | ||||
Mexico | ||||
Europe | Germany | |||
United Kingdom | ||||
France | ||||
Russia | ||||
Rest of Europe | ||||
Asia-Pacific | China | |||
India | ||||
Japan | ||||
South Korea | ||||
Australia | ||||
Rest of Asia-Pacific | ||||
South America | Brazil | |||
Rest of South America | ||||
Middle East and Africa | Middle East | United Arab Emirates | ||
Saudi Arabia | ||||
Israel | ||||
Rest of Middle East | ||||
Africa | South Africa | |||
Rest of Africa |
OEMS |
Airlines |
MRO |
Engines |
Avionics |
Aircraft Structures |
Environmental Control and Ancillary Systems |
Hardware | Sensors |
Avionics | |
Flight Data Managemnet Systems | |
Connected Aircarft Solutions | |
Ground Services | |
Software | Onboard Software |
Diagnostics Analytics | |
Prognostics Analytics | |
Services | Integration and Customisation |
MRO/Condition-Monitoring Services |
Line-fit |
Retrofit |
Onboard |
Ground-based |
Fixed-Wing | Commercial Aviation | Narrowbody Aircraft | |
Widebody Aircraft | |||
Regional Transport Aircraft | |||
Military Aviation | Fighter Aircraft | ||
Transport Aircraft | |||
Special Mission Aircraft | |||
Business and General Aviation | Business Jets | ||
Light Aircraft | |||
Rotary Wing | Commercial Helicopters | ||
Military Helicopters | |||
Military Unmmaned Aerial Vehicles | |||
Advanced Air Mobility |
North America | United States | ||
Canada | |||
Mexico | |||
Europe | Germany | ||
United Kingdom | |||
France | |||
Russia | |||
Rest of Europe | |||
Asia-Pacific | China | ||
India | |||
Japan | |||
South Korea | |||
Australia | |||
Rest of Asia-Pacific | |||
South America | Brazil | ||
Rest of South America | |||
Middle East and Africa | Middle East | United Arab Emirates | |
Saudi Arabia | |||
Israel | |||
Rest of Middle East | |||
Africa | South Africa | ||
Rest of Africa |
Key Questions Answered in the Report
What is the current size of the Aircraft Health Monitoring Systems market?
The market stood at USD 6.96 billion in 2025 and is projected to reach USD 9.60 billion by 2030 on a 6.63% CAGR trajectory.
Which segment leads the Aircraft Health Monitoring Systems market?
Airlines held the top position with 54.25% market share in 2024, driven by direct operational-reliability pressures and embedded monitoring in new aircraft.
Which is the fastest growing region in Aircraft Health Monitoring Systems Market?
Asia Pacific is estimated to grow at the highest CAGR over the forecast period.
Why is Asia-Pacific the fastest-growing region?
Rapid fleet expansion, new-aircraft deliveries, and digitalization programs are expected to push Asia-Pacific to a 7.25% CAGR through 2030.
What role does software play in market growth?
Software analytics are forecasted to post an 8.45% CAGR as machine-learning tools transform sensor data into actionable maintenance insights, shifting value capture from hardware to algorithms.
How will advanced air mobility influence future demand?
EVTOL programs are integrating health monitoring from design inception, creating a high-growth sub-segment that is projected to expand at 10.54% CAGR and drive innovation for traditional aviation.
Page last updated on: June 25, 2025