CFM LEAP Engine Production, Durability, and Spare Parts Outlook for 2025

CFM LEAP Engine: Production, Durability, and Spare Parts Outlook for 2025

Aviation Week editors Sean Broderick, James Pozzi, and Lee Ann Shay recently examined the current status and future prospects of the CFM LEAP 1A and 1B engine programs. Their discussion centered on key aspects such as durability enhancements, production ramp-up, and the evolving dynamics of the aftermarket sector.

With over 3,500 aircraft powered by CFM LEAP engines currently in operation—a figure expected to double by 2030—CFM faces mounting pressure to meet increasing demand while addressing ongoing technical challenges. Safran, which co-manages the CFM joint venture alongside General Electric, forecasts a 15 to 20 percent increase in LEAP engine deliveries this year, reflecting cautious optimism despite recent obstacles.

Durability Challenges and Mitigation Efforts

Since the introduction of the LEAP-1A in August 2016 and the LEAP-1B in May 2017, the program has encountered several durability issues, though it has largely avoided the severe crises experienced by some competitors, such as the geared turbofan and Rolls-Royce Trent 1000 engines. One of the most pressing concerns has involved the high-pressure turbine stage one shrouds, which operate under extreme thermal conditions. Early operational data revealed coating deficiencies on these components, prompting CFM to implement improved coatings starting in 2019. To date, more than 70 percent of the affected fleet has undergone retrofitting, with efforts ongoing to complete this process.

Another significant issue pertained to bearing upgrades on driveshafts, particularly within the LEAP-1B engines installed on Boeing 737 MAX aircraft. These bearings were implicated in a limited number of in-flight engine shutdowns. CFM has since retrofitted approximately 95 percent of the impacted fleet, markedly reducing the likelihood of further incidents.

Attention is now focused on the combustion chamber, where accelerated degradation has resulted in increased maintenance demands and elevated operational costs for airlines. In response, CFM is actively testing a new, more durable combustion chamber coating designed to extend inspection intervals and mitigate wear.

Supply Chain Constraints and Market Implications

The technical challenges faced by the LEAP program have been exacerbated by persistent supply chain disruptions, which have slowed the pace of engine deliveries. Market data indicates a slight decline in deliveries as CFM and its partners work to resolve both supply and durability issues. This environment has encouraged competitors to explore enhancements to their own engine platforms, potentially intensifying competition in the narrowbody aircraft market, where reliability and efficiency remain paramount.

Outlook for 2025 and Beyond

Despite these challenges, the future outlook for the LEAP program remains constructive. The planned increase in production capacity, coupled with expanded aftermarket opportunities and ongoing technical refinements, positions CFM to satisfy growing market demand while addressing operator concerns. As the aviation industry advances into 2025, the effectiveness with which CFM balances production ramp-up, durability improvements, and supply chain management will be critical in shaping the competitive landscape for years ahead.