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High-temperature fuel cells for ZeroAvia’s megawatt-scale ZA2000 powertrain.
Artificial intelligence applications and alternative aircraft propulsion systems are both greatly changing the aviation aftermarket.
Given that aircraft engine MRO should make up 45 per cent of the projected $29 billion commercial aviation expenditures this year, according to Aviation Week’s 2025 Commercial Fleet & MRO Forecast, introducing electric, hybrid-electric and hydrogen propulsion to the market could make a dent in that. Or MRO could expand as aircraft conversions and advanced air mobility (AAM) take off.
Manufacturers, MROs, the supply chain and aviation maintenance technician schools are laying the groundwork for change because electric engines, in particular, should proliferate in the next few years as regulators certify more of them.
Safran’s ENGINeUS 100B1 received European Union Aviation Safety Agency approval in February at 150 kW for small aircraft, but the manufacturer is working on a 180-kW version that could power 19-seat aircraft. MagniX is converting a 50-seat De Havilland Canada Dash 7 to hybrid-electric propulsion, and ZeroAvia is developing the hydrogen-electric ZA2000 engine with hopes to fly it on the larger 70-80-seat Dash 8-400.
Electric or hybrid-electric propulsion is the power choice for AAM manufacturers. While the field is narrowing, several are flying and logging certification milestones. EHang, Volocopter, Beta Technologies, Joby Aviation and Archer top SMG Consulting’s AAM Reality Index, which measures a company’s viability of making it to market. EHang is already delivering aircraft in China, and the others plan certification for 2026-27.
As more engine types and battery systems are certified, the market’s potential looks more exciting—but the charging infrastructure and everything needed to support operations must proliferate, too. Aviation Week editors Lindsay Bjerregaard, James Pozzi and Graham Warwick outline in detail in our cover story the electric market’s status.
Warwick also wrote this month’s Engineered feature on hydrogen cell development. He explains why the proton-exchange membrane fuel cell is emerging as the top choice for aviation applications. If operating temperature and power density challenges can be overcome, these engines could rival turbines. The article spells out clearly why hydrogen could be powering an aircraft in which you might fly someday.
All these new systems need to be maintained, but new technicians in the U.S. are having a hard time taking FAA certification oral and practical exams because of a shortage of designated mechanic examiners and slots at Knowledge Testing Centers, which are all run or approved by testing company PSI. Lindsay Bjerregaard’s in-depth feature explores the situation. Given the shortage of A&Ps in most places of the world, including the U.S., these problems need to be resolved.
On a positive training note, ATS has been experimenting with artificial intelligence (AI) to develop tools and training for technicians in-house. Just as AI can streamline day--to-day processes, it could enhance training through adaptive learning paths, virtual reality, just-in-time learning, risk-scenario generation and fault-prediction scenarios, among others.
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