The aerospace industry is facing increasing pressure to reduce its environmental impact. While much of the focus has been on cutting emissions during an aircraft’s service life, what happens after retirement is equally important. Each aircraft is made up of roughly 350,000 individual parts, and over time, these parts inevitably wear out, requiring replacement—a process that poses challenges in balancing operational needs with environmental responsibility.
Many retired aircraft are dismantled to recover valuable materials and components, but current practices often fall short of their sustainability potential. Outdated manufacturing methods, limited regulations, and a lack of circular economy principles mean there is significant room for improvement in recycling, reusing, and repurposing materials.
Adopting sustainable practices, such as designing for easier recycling, sourcing responsibly, and optimising energy use, offers a path towards a greener future. By rethinking how aircraft are built, maintained, and decommissioned, the aerospace sector can reduce waste, lower costs, and contribute to long-term environmental goals.
What’s currently happening to retired aircraft?
An aircraft usually stays in service for 20 to 25 years. Over this time, it will cover around 40 million kilometres, which is more than 1,000 trips around the world. Some long-haul planes can travel over 100 million kilometres 1. Once their operational lifespan ends, many aircraft are retired to storage facilities or “aircraft graveyards,” where they are carefully dismantled to recover usable parts. While this process is essential for reusing valuable materials and maintaining safety standards, it also poses environmental challenges. Retired aircraft often contain hazardous substances like lead, asbestos, and chemicals that, if not managed correctly, can harm soil and water quality.
However, not all retired aircraft are simply scrapped. Some are sold to smaller airlines or converted for cargo operations, particularly in regions where older aircraft are still in demand. Many are dismantled and recycled, with up to 85% of their materials being reused in new applications 2. Metals such as aluminium and titanium are processed and repurposed, while other components find uses in products like electronics. High-value parts, including engines and landing gear, are often refurbished and returned to service, provided their maintenance history is well-documented.
These practices not only make recycling retired aircraft more cost-effective, but also highlight ongoing efforts to reduce waste and promote sustainability in aerospace.
Aerospace sustainability challenges: The regulations
Despite ongoing efforts to improve recycling, balancing sustainability in aerospace with high performance and efficiency remains a significant challenge. A key concern in the aerospace supply chain is extending the life of expensive, reusable parts. Critical components such as engines, airframes, avionics, landing gear, and high-performance items like turbine blades are among the most costly parts of an aircraft. This is due to the advanced materials, precision manufacturing, and complex technologies required in their production.
Recycling and reusing these parts are essential for both cost efficiency and preserving the environment. This process not only conserves raw materials but also reduces the environmental impact of aviation by cutting the need for energy-intensive material extraction. Experts say reusing parts can save airlines up to 40% compared to purchasing new ones, making it both cost-effective and eco-friendly 3. By diverting materials from landfills, aircraft recycling helps reduce waste, conserve landfill space, and lower greenhouse gas emissions, contributing to a more sustainable aviation sector. Furthermore, it plays a vital role in helping the aviation industry meet its commitment to achieving net-zero emissions by 2050.
Currently, however, the aerospace industry lacks specific regulations governing the recycling and reuse of materials. The European Union Aviation Safety Agency (EASA) notes that, unlike the strict EU rules for managing waste from end-of-life vehicles like cars and trucks, there are no regulations for aircraft. When an aircraft is decommissioned, its parts are treated as general waste, subject only to broad waste management laws based on the materials involved 4. This lack of clear guidance means the industry does not yet have standardised processes for recycling or reusing aircraft components in a way that reduces waste and enhances sustainability.
Furthermore, EASA highlights that there are no requirements for aviation companies to design aircraft parts with recycling or reuse in mind 5. Along with Sustain Air who say ‘At the moment, there is no real sustainability in how materials are used in the aviation and aerospace sectors 6’. Aircraft manufacturing typically depends on steel rivets, which are difficult to disassemble and recycle. Additionally, two distinct types of casting processes are used, which cannot be combined, leading to materials that are not easily reusable. Moreover, the production process remains traditional, energy-consuming, and wasteful, and fails to fully leverage more sustainable manufacturing options such as additive manufacturing and high-pressure die casting. Many aircraft are also not designed to facilitate the recovery of valuable materials or the reuse of parts at the end of their lifespan.
Benefits of the circular economy for aerospace parts
Sustain Air’s 7 focus on the circular economy highlights the vast potential for sustainability in aerospace through the 4 R’s—redesign, repair, reuse, and recycle. The principle of circular aviation starts from the design phase, which is a crucial shift from the conventional linear approach. Typically, the aerospace industry prioritises the initial value and performance of aircraft in their “first life,” without considering their full lifecycle or potential for reuse in subsequent stages. Circular design, however, recognises that an aircraft can have multiple “lives,” each contributing to a more sustainable future.
By implementing circular design principles, aerospace manufacturers and operators can plan for the end-of-life phase from the outset, ensuring that parts can be repaired, reused, or recycled effectively, rather than disposed of. This shift not only enhances sustainability by lowering waste and reducing raw material consumption but also minimises the environmental impact of manufacturing and operation. For instance, using materials that are easier to recycle or repurpose helps close the loop of production and consumption, contributing to a more sustainable ecosystem.
The World Economic Forum (WEF) predicts that the circular economy could bring economic benefits of up to $4.5 trillion by 2030 8. Transitioning to a circular economy can lead to significant cost reductions, particularly in raw materials, waste management, and disposal. Recycled materials tend to be less expensive than newly sourced ones, and reusing components generates additional savings. This approach also opens new revenue streams, such as the sale of recycled materials or refurbished parts.
For the aerospace industry, these benefits are particularly impactful. By reusing and remanufacturing aircraft components, companies can extend the lifespan of their fleets, reduce reliance on new manufacturing, and lower operational expenses. This not only cuts material and waste management costs but also alleviates the financial burden of purchasing new parts, resulting in long-term financial sustainability.
Adopting circular economy principles in the aerospace sector is a win-win, driving sustainability while also offering significant economic benefits. By redesigning aircraft for longevity, embracing repair and reuse, and recycling materials, the aerospace industry can transform its environmental impact and improve its financial performance. Circular aviation not only represents a forward-thinking approach to sustainability but also a smart business strategy that supports both environmental and economic goals.
Key actions for driving sustainability in aerospace
Jen Hunt, Group Sustainability Director at Unipart, outlines some practical steps to encourage sustainability in aerospace:
- Think circular
Look at every product, material, and process to find ways to reduce waste. Focus on reusing, repairing, refurbishing, and recycling wherever possible. - Design for sustainability
Build sustainability into the design of new products and processes right from the start to minimise waste and maximise efficiency. - Source responsibly
Understand the journey of the goods and services you use. Supplier activities often account for most of an organisation’s carbon footprint. Use strong procurement practices to ensure transparency and reduce emissions from your supply chain. - Optimise energy use
Most emissions come from energy used in operations. Switching to renewable energy sources can make a big impact quickly. - Greener transport options
Use electric vehicles or alternative fuels, such as Hydrotreated Vegetable Oil (HVO), to lower emissions from transportation. - Conserve water
Water scarcity is a growing issue. Take steps to reduce water usage across your operations and supply chain. - Collaborate for solutions
Transitioning to sustainable supply chains requires teamwork. Sharing knowledge and working together across industries helps solve common challenges faster and more effectively.
The aerospace industry has a critical role to play in shaping a sustainable future. By embracing innovative practices and circular economy principles, it can significantly reduce its environmental impact while creating new economic opportunities.
References
- Aviation benefits – Circular economy – Aviation: Benefits Beyond Borders. 2024
- Business traveller – Does aircraft age matter?. 2024
- Aviation Business News – The environmental impact and economic advantages of aircraft recycling. 2024
- Easa – Sustainability in the end-of-life phase of aircraft. 2025
- Easa – Sustainability in the end-of-life phase of aircraft. 2025
- Sustain air – Sustainability Snapshots: Circular economy, the next frontier for aerospace and aviation sectors.
- Sustain air –Sustainability Snapshots: Circular design for aircraft.
- Weforum – Making the $4.5 trillion circular economy opportunity a reality. 2024