Aviation insurance claims costs continued to increase during 2025-2026, with rises recorded across every category tracked by McLarens Aviation’s latest Aviation Claims Cost Index.

Compiled from claims data gathered across McLarens Aviation’s network of more than 30 offices worldwide, the index recorded annual increases ranging from 6% to 10.8%. The largest rise was in major repairs, OEM and aircraft on ground costs. Labour costs for light aircraft rose 10.5%, while light aircraft piston propeller strike costs increased 10.3%. MRO facilities recorded an 8.2% increase.

Engine-related costs also continued to climb, with fan blade costs rising 7.5% and one widely used engine type seeing fan blade costs increase 135% over seven years.

“What stands out this year is the consistency of the trend rather than any single spike,” said John Bayley, global technical director at McLarens Aviation. “Looking at the last three years of data side-by-side, there’s no real peak or trough, it’s a steady, year-on-year increase. This is no longer a post-pandemic correction; it reflects a genuine structural shift in how aircraft are maintained, repaired and resourced.”

The index highlights continued pressure from engineering skills shortages, constrained supplies of specialist materials and limited capacity at repair facilities.

---