2026 Commercial Aerospace Outlook: A New Era for Supply Chain and MRO

Commercial aerospace is on track for significant transformation in 2026, led by two distinct industry priorities.

On the ground, digital resilience tops the agenda, with milestones like:

• 3D printing comes to the supply chain’s rescue
• Cybersecurity comes to the fore following major breaches in 2025
• AI eases labor shortages

In contrast, the sky is no longer the limit, as the rise in commercial space tourism unlocks a new space MRO and logistics market.

Why 2026 could be a breakthrough year for 3D printing in supply chain

Supply chain challenges for spare parts availability persist in commercial aviation. Leading airlines and air operators to think outside the box and adopt innovative manufacturing strategies to maintain operational readiness.

One potential solution was to use Parts Manufacturer Approval (PMA) parts, but some airlines face considerable hurdles here as lessors often refuse to allow PMA parts on their aircraft. However, other parts supply solutions are on the horizon.

Print parts here and now

There are promising signs ahead of ongoing efforts by FAA and EASA regulators to clarify how 3D printed parts can be used in certain applications.

Additive manufacturing combined with the digital thread could help solve supply chain bottlenecks by allowing parts to be produced when and wherever they’re needed.

In particular, this technology offers a solution for maintaining older aircraft, as digital files replace the need to store molds and assembly lines.

We are already seeing this shift with certified 3D-printed engine components and heat exchangers that handle super-complex geometries not achievable through traditional manufacturing, such as those on the GE Catalyst turboprop engine.

Why cybersecurity is key for effective modernization in aerospace

The entire commercial aviation network is critical. Its high-value infrastructure ensures the effective movement of people and goods around the world.

The industry’s vulnerability to cyberattacks and their ability to cause widespread disruption has been underscored by recent examples, like the ransomware attack in 2025 that disabled check-in systems across Europe.

The crux of the issue is that aviation is still only digitally mature in part. The vulnerability lies in the "middle section"—where airline aircraft, and ground systems have been partially modernized but not brought fully up to date with cybersecurity practices.

Is your software provider cyber-conscious?

This year, recent attacks and emphasis on the essential role aviation plays in world affairs could motivate airlines to push for digital modernization across the entire industry—with airlines and airports implementing up-to-date cybersecurity practices for all operational systems.

Airlines and MROs must ensure their software provider constantly adopts a clear security posture, constantly addressing vulnerabilities with frequent updates using an evergreen approach, and ideally, designing out vulnerabilities from the beginning.

How industrial AI enables technicians to do more with less

Despite technician certifications rising, The Pipeline Report and Oliver Wyman show increasing demand, and projected retirements are expected to leave commercial aviation with 10% fewer certified mechanics than needed in 2025.

What does the new digital MRO workforce look like?

The ideal agent will be able to help navigate reference documentation like:

• AMMs
• CMMs
• Troubleshooting manuals
• IPC

These agents navigate while pulling up pertinent Airworthiness Directives (ADs) or Service Bulletins (SBs). The co-pilot can then use this information to:

• Determine whether it’s a potential recurring fault
• Identify whether repairs failed to work previously
• Suggest candidates for troubleshooting tasks
• Request the required parts automatically

In 2026, expect troubleshooting agents to move into deployment within the maintenance operations of airlines and MROs. These agents can serve as digital co-pilots that enhance the productivity of the workforce.

How the MRO market can enter a new era in space flight

An aftermarket opportunity is emerging for MROs, driven by developments like:

• Proliferation of satellites
• Rise of reusable vertical-landing rockets
• Commercial space tourism with reusable spaceflight vehicles

Together, these shifts are creating an entirely new MRO market for launch platforms themselves, which now require a formal sustainment process.

What opportunities space travel presents for MROs

Launch and space-platform MRO is rapidly emerging as the next frontier. For the most part, orbital vehicles have been treated as disposable assets with a finite operational life.

The advent of self-healing materials is beginning to shift this paradigm by enabling spacecraft to autonomously repair themselves in orbit.

Blue Origin’s multi-use Blue Ring platform illustrates how reusable vehicles will create entirely new sustainment markets.

The ripple effect over the coming years is that these once disposable space assets will require sustainment and support strategies, which can be mitigated if maintenance s built into asset management lifecycles. This can achieve:

• Maximized availability
• Improved efficiency
• Reduced cost of space operations

This year presents huge opportunities for commercial aerospace, but a lot of these depend on the industry and software providers stepping up to the digital plate. The technology, supporting software and digital tools are there to be capitalized on.