Aircraft Health Monitoring Systems Market Size & Share Analysis - Growth Trends & Forecasts (2025 - 2030)

The Aircraft Health Monitoring Systems Market Report is Segmented by End User (OEMs, Airlines, and MRO), Subsystem (Engines, and More), Component (Hardware, Software, and Services), Fit (Line-Fit and Retrofit), Transmission Mode (Onboard and Ground-Based), Aircraft Type (Fixed-Wing, and More), and Geography (North America, Europe, Asia-Pacific, and More). The Market Forecasts are Provided in Terms of Value (USD).

Aircraft Health Monitoring Systems Market Size and Share

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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.

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.

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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.

Aircraft Health Monitoring Market: Market Share by Fit
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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.

Aircraft Health Monitoring Market  Growth Rate by Region
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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

  1. The Boeing Company

  2. Honeywell International Inc.

  3. RTX Corporation

  4. Safran SA

  5. General Electric Company

  6. *Disclaimer: Major Players sorted in no particular order
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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.

Table of Contents for Aircraft Health Monitoring Systems Industry Report

1. INTRODUCTION

  • 1.1 Study Assumptions and Market Definition
  • 1.2 Scope of the Study

2. RESEARCH METHODOLOGY

3. EXECUTIVE SUMMARY

4. MARKET LANDSCAPE

  • 4.1 Market Overview
  • 4.2 Market Drivers
    • 4.2.1 Predictive maintenance imperative
    • 4.2.2 Regulatory mandates for flight and FOQA data
    • 4.2.3 Rapid commercial fleet expansion
    • 4.2.4 Connected-aircraft and IoT ecosystem maturity
    • 4.2.5 Digital-twin-driven virtual sensor modelling
    • 4.2.6 On-board edge-AI avionics processors
  • 4.3 Market Restraints
    • 4.3.1 Cyber-security and data-integrity risks
    • 4.3.2 High capex/retrofit integration cost
    • 4.3.3 Operator-lessor-OEM data-ownership disputes
    • 4.3.4 Sensor ruggedization limits on ageing fleets
  • 4.4 Value Chain Analysis
  • 4.5 Regulatory Landscape
  • 4.6 Technological Outlook
  • 4.7 Porter’s Five Forces Analysis
    • 4.7.1 Threat of New Entrants
    • 4.7.2 Bargaining Power of Buyers
    • 4.7.3 Bargaining Power of Suppliers
    • 4.7.4 Threat of Substitutes
    • 4.7.5 Competitive Rivalry

5. MARKET SIZE AND GROWTH FORECASTS (VALUE)

  • 5.1 By End User
    • 5.1.1 OEMS
    • 5.1.2 Airlines
    • 5.1.3 MRO
  • 5.2 By Sub-system
    • 5.2.1 Engines
    • 5.2.2 Avionics
    • 5.2.3 Aircraft Structures
    • 5.2.4 Environmental Control and Ancillary Systems
  • 5.3 By Component
    • 5.3.1 Hardware
    • 5.3.1.1 Sensors
    • 5.3.1.2 Avionics
    • 5.3.1.3 Flight Data Managemnet Systems
    • 5.3.1.4 Connected Aircarft Solutions
    • 5.3.1.5 Ground Services
    • 5.3.2 Software
    • 5.3.2.1 Onboard Software
    • 5.3.2.2 Diagnostics Analytics
    • 5.3.2.3 Prognostics Analytics
    • 5.3.3 Services
    • 5.3.3.1 Integration and Customisation
    • 5.3.3.2 MRO/Condition-Monitoring Services
  • 5.4 By Fit
    • 5.4.1 Line-fit
    • 5.4.2 Retrofit
  • 5.5 By Transmission Mode
    • 5.5.1 Onboard
    • 5.5.2 Ground-based
  • 5.6 By Aircraft Type
    • 5.6.1 Fixed-Wing
    • 5.6.1.1 Commercial Aviation
    • 5.6.1.1.1 Narrowbody Aircraft
    • 5.6.1.1.2 Widebody Aircraft
    • 5.6.1.1.3 Regional Transport Aircraft
    • 5.6.1.2 Military Aviation
    • 5.6.1.2.1 Fighter Aircraft
    • 5.6.1.2.2 Transport Aircraft
    • 5.6.1.2.3 Special Mission Aircraft
    • 5.6.1.3 Business and General Aviation
    • 5.6.1.3.1 Business Jets
    • 5.6.1.3.2 Light Aircraft
    • 5.6.2 Rotary Wing
    • 5.6.2.1 Commercial Helicopters
    • 5.6.2.2 Military Helicopters
    • 5.6.3 Military Unmmaned Aerial Vehicles
    • 5.6.4 Advanced Air Mobility
  • 5.7 By Geography
    • 5.7.1 North America
    • 5.7.1.1 United States
    • 5.7.1.2 Canada
    • 5.7.1.3 Mexico
    • 5.7.2 Europe
    • 5.7.2.1 Germany
    • 5.7.2.2 United Kingdom
    • 5.7.2.3 France
    • 5.7.2.4 Russia
    • 5.7.2.5 Rest of Europe
    • 5.7.3 Asia-Pacific
    • 5.7.3.1 China
    • 5.7.3.2 India
    • 5.7.3.3 Japan
    • 5.7.3.4 South Korea
    • 5.7.3.5 Australia
    • 5.7.3.6 Rest of Asia-Pacific
    • 5.7.4 South America
    • 5.7.4.1 Brazil
    • 5.7.4.2 Rest of South America
    • 5.7.5 Middle East and Africa
    • 5.7.5.1 Middle East
    • 5.7.5.1.1 United Arab Emirates
    • 5.7.5.1.2 Saudi Arabia
    • 5.7.5.1.3 Israel
    • 5.7.5.1.4 Rest of Middle East
    • 5.7.5.2 Africa
    • 5.7.5.2.1 South Africa
    • 5.7.5.2.2 Rest of Africa

6. COMPETITIVE LANDSCAPE

  • 6.1 Market Concentration
  • 6.2 Strategic Moves and Funding
  • 6.3 Market Share Analysis
  • 6.4 Company Profiles (includes Global-level Overview, Market-level Overview, Core Segments, Financials, Strategic Information, Market Rank/Share, Products and Services, Recent Developments)
    • 6.4.1 The Boeing Company
    • 6.4.2 General Electric Company
    • 6.4.3 RTX Corporation
    • 6.4.4 Honeywell International Inc.
    • 6.4.5 Safran SA
    • 6.4.6 Rolls-Royce plc
    • 6.4.7 Meggitt PLC
    • 6.4.8 Curtiss-Wright Corporation
    • 6.4.9 FLYHT Aerospace Solutions Ltd.
    • 6.4.10 Lufthansa Technik AG
    • 6.4.11 MTU Aero Engines AG
    • 6.4.12 Ultra Precision Control Systems (Ultra Group)
    • 6.4.13 Eve Holding, Inc.
    • 6.4.14 Airbus SE
    • 6.4.15 EXSYN Aviation Solutions
    • 6.4.16 RSL Electronics Ltd.

7. MARKET OPPORTUNITIES AND FUTURE OUTLOOK

  • 7.1 White-space and Unmet-Need Assessment
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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
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
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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

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