Aviation Supply Crisis Hits Working Families' Travel Costs

The aviation industry's ongoing supply chain crisis is driving up travel costs for ordinary families across Ireland and Europe, as airlines struggle with delays and shortages that have become the troubling 'new norm' since the pandemic.

Years after Covid-19 first disrupted global travel, the industry continues to grapple with severe supply bottlenecks that are forcing airlines to keep older, less efficient aircraft in service for longer periods. This reality is hitting passengers in their pockets as airlines pass on increased operational costs.

Record Demand Meets Supply Shortages

Global air passenger traffic reached record highs in 2025, climbing 9.3% above pre-pandemic levels, according to the International Air Transport Association (IATA). Yet this surge in demand has collided with a supply chain still struggling to recover from years of disruption.

Jeffrey Lam, chief operating officer at ST Engineering, the world's largest aircraft maintenance provider, expressed frustration at this week's Singapore Airshow: "We are afraid that this new norm will stay, which is completely unacceptable."

The human cost is clear. Airlines are keeping older planes flying for two years longer than usual, pushing up fuel, maintenance and inventory costs by an estimated €10.2 billion in 2025 alone. These costs inevitably flow through to ticket prices, making travel less accessible for working families.

Geopolitical Fallout Compounds Crisis

The situation has been worsened by geopolitical tensions, particularly Russia's war in Ukraine, which cut off access to Russian titanium exports that previously supplied about half the global market. This has created critical shortages in aircraft engine manufacturing.

Paul Wingfield from US-based Future Metals reported that lead times for essential materials like titanium and nickel tubing now stretch 50 to 60 weeks, compared to just 20 weeks before the pandemic. "The mills can't make enough to catch up because they stopped producing for four years," he explained.

Airlines Forced into Costly Workarounds

Airlines are being forced into expensive contingency measures. Singapore Airlines' budget carrier Scoot is now securing spare engines at its own expense to mitigate potential disruptions, costs that ultimately impact fare structures.

IATA Director General Willie Walsh voiced the industry's frustration: "It's very frustrating, and when you see this massive additional cost being borne by airlines, you know it really is time for these key suppliers to get their act together."

Engine manufacturer CFM International, a joint venture between GE Aerospace and Safran, has increased production by 25% in 2025, with plans for at least 10% annual growth. Yet CEO Gael Meheust acknowledged the challenge: "The demand is at a level that we have never imagined."

Impact on European Connectivity

For Ireland and our European neighbours, these supply chain disruptions threaten the connectivity that modern economies depend upon. As airlines struggle with delayed deliveries from Airbus and Boeing, routes that connect Irish communities to the wider European project face potential disruption.

The crisis highlights the need for strategic European industrial policy that reduces dependence on volatile global supply chains and ensures essential services like aviation remain accessible to all citizens, not just the wealthy.

While some suppliers have found opportunities in this chaos, with Chinese manufacturers gaining market share through competitive pricing, the broader impact on European families and businesses remains deeply concerning.