Stuart Illian
Stuart Illian is the Co-founder and Chief Aviation Officer COO of Bluetail, a leading digital aircraft records platform. He has held leadership roles at Apple, Deloitte, Lockheed Martin and Textron. He managed Apple’s $100 million software business, played a key role in ProFlight’s growth before its Textron acquisition and helped launch XOOM.com’s IPO. Stuart holds an FAA Commercial Pilot License and a BSBA in Accounting from Ohio State, with a minor in Aviation Management. He also attended the University of North Dakota for pilot training.
Key Trends in Business Aviation Maintenance for 2025
The business aviation maintenance landscape is rapidly evolving. Stuart Illian explores 2025 trends, from AI’s-driven maintenance to workforce challenges and regulatory shifts.
Lately, in conversations with industry colleagues, one thing is clear—business aviation maintenance is changing fast. Technology, labor shortages, political headwinds and supply chain issues are reshaping the landscape.
Here’s a look at some key trends currently shaping the industry:
The Growing Importance of a Maintenance Tech Stack
Aviation maintenance is becoming increasingly digitalized, with operators adopting integrated tech stacks to improve efficiency. Advanced Enterprise Resource Planning (ERP) and Mx-tracking systems, predictive maintenance software and electronic record-keeping solutions are reducing administrative burdens and improving fleet reliability.
AI-driven analytics, combined with aircraft Central Maintenance Computers (CMPs), are also optimizing maintenance schedules by predicting failures before they occur. These tools streamline compliance and enhance operational decision-making, making aircraft maintenance more proactive rather than reactive.
Managing Maintenance with a Labor Shortage
The ongoing shortage of skilled aviation maintenance technicians remains a challenge, forcing companies to rethink how they attract and retain talent.
Business aviation organizations are investing in apprenticeship programs and partnerships with technical schools. They’re also attracting new talent into the workforce with improved compensation packages.
At the same time, aviation MROs and operators are leveraging automation, better planning tools and AI-powered scheduling to maximize efficiency with a lean workforce. Simplifying administrative tasks with digital solutions is also helping technicians focus more on hands-on maintenance rather than paperwork.
The Impact of DOGE
The Department of Government Efficiency (DOGE) initiative is looking to drive greater efficiency which could translate into a potentially downsized FAA. (I’ve already heard from more than one operator that delays in new aircraft conformity inspections are to be expected.)
DOGE’s focus on streamlining regulatory processes, reducing paperwork and encouraging automation will no doubt put more pressure on MROs and operators in the short to medium term. With reduced FAA resources, maintenance teams executing repairs and overhauls more swiftly, reducing aircraft downtime and enhancing operational efficiency, will take on added importance.
Continued Parts & Supply Chain Challenges
Supply chain disruptions continue to impact aviation maintenance, with longer lead times for critical parts and rising costs. The industry is responding by increasing the use of 3D printing for on-demand manufacturing, parts pooling programs, and deeper supplier partnerships.
Companies are also stockpiling key components to avoid delays and investing in predictive analytics to better anticipate part needs before shortages arise.
Expansion of Aviation Maintenance Capacity
To address growing demand and operational pressures, major MROs, OEMs, and operators are expanding their maintenance facilities and capabilities. More hangars, service centers, and mobile maintenance units are being introduced to handle increasing fleet sizes and maintenance requirements.
This expansion is being driven by existing industry Mx players and (very) large operators seeking faster turnaround times and improved service availability.
Looking Ahead
Business aviation maintenance will continue its transformation in 2025. Companies that embrace tech stack integration—eliminating duplication, cutting errors and saving time—will gain an edge. Success will also hinge on workforce development, navigating regulations and strengthening supply chains. Those who adapt will thrive in an industry that never stands still.