Aircraft Repairs Are Getting Pricier—Here’s How To Stay Prepared in 2025

If you’ve noticed aircraft parts taking longer to arrive—or costing more than ever—you’re not alone. The cost of aircraft maintenance and repair has been steadily rising over the past couple of years, and in 2025, it’s a trend that continues to impact owners, operators, and insurers alike.

But while headlines might focus on price hikes and supply chain issues, this article is about practical steps you can take to protect your aircraft, reduce your risk, and make sure your insurance coverage works for you—not against you.

Why Are Aircraft Repairs So Expensive Right Now?

Between labor shortages, part delays, and rising material costs, maintenance and repair operations (MROs) are facing pressure across the board. Industry data from McLarens and other aviation specialists shows:

• Labor costs for general aviation repairs are up 15–20%
• OEM parts are seeing consistent year-over-year price increases
• Engine repairs and prop strikes are among the most expensive claims, with some costs rising 30–40%

And while inflation is part of the story, so is complexity. Aircraft are increasingly high-tech, which means even minor repairs can require specialized tools, longer inspections, and costly replacements.

What This Means for Aircraft Owners

Whether you’re a private pilot with a single-engine piston or managing a fleet of turbine aircraft, higher repair costs can affect you in two big ways:

• Claims Are More Expensive – A simple mishap on the ramp or a bird strike could cost significantly more to fix than it would have a few years ago.
• Downtime Is Longer – With backlogged parts and busy MRO schedules, “aircraft on ground” time is stretching out—sometimes for weeks.

Neither of these factors automatically drives up insurance premiums. But they do increase your overall exposure and underscore the importance of being strategic, not reactive.

5 Ways To Stay Ahead—and Keep Your Insurance Working for You

Rising repair costs don’t have to catch you off guard. With a few proactive strategies, aircraft owners can reduce their exposure to costly repairs, avoid unnecessary downtime, and make the most of their insurance coverage. These aren’t just theoretical tips—they’re practical actions that can help you stay in control, even as the market shifts. Whether you fly recreationally or manage a fleet, here’s how to stay protected in 2025 and beyond.

1. Prioritize Preventative Maintenance

A small issue caught early is often far less expensive than one that grows into a major claim. Following your aircraft’s maintenance schedule closely, addressing wear-and-tear items before they fail, and doing thorough pre- and post-flight inspections can all reduce the likelihood of an unexpected repair—and a costly insurance claim.

2. Build Relationships With Trusted Repair Shops

When parts are scarce and labor is tight, it helps to already have a good working relationship with a reliable MRO. Some facilities are better equipped than others to source parts quickly or recommend alternate solutions. Your insurance provider may also be able to recommend preferred shops with a strong track record.

3. Stock Common Replacement Parts (If Possible)

This won’t work for everyone, but if you fly frequently or operate a fleet, consider keeping high-turnover items like tires, filters, or spark plugs on hand. In regions with long delivery lead times, this can significantly cut down on repair delays.

4. Talk to Your Broker About Your Coverage

You don’t have to wait until renewal to get clarity. Ask your broker or agent:

• Are my hull limits keeping up with current aircraft values?
• Would my policy cover extended downtime due to parts delays?
• Can I access preferred repair facilities or services?

Being proactive about coverage now can prevent surprises down the road.

5. Keep Good Records and Communicate Quickly

If you do need to file a claim, the more documentation you have (photos, maintenance logs, incident details), the faster your claim can be resolved. Reporting damage promptly and keeping your insurer informed of any delays can also help reduce stress—and get you back in the air sooner.

Final Thoughts

The aviation industry is no stranger to cycles—and while repair costs are high right now, there are plenty of ways to stay protected. At the end of the day, having the right policy, good maintenance habits, and a trusted insurance partner can make all the difference.

If you’re unsure whether your current coverage still fits your aircraft’s needs, or you just want to talk through your options, we’re here to help. Reach out any time to review your policy or ask questions about managing risk in today’s aviation environment.

For informational purposes only.