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ReMAP · Project

Smart Aircraft Maintenance That Fixes Problems Before They Ground Your Fleet

transportPilotedTRL 5
h2020-remap.eu

Imagine your car could tell you exactly when a part is about to fail — not based on a calendar schedule, but based on how it's actually performing right now. ReMAP built that kind of smart health monitoring for aircraft. Instead of pulling planes out of service every X months whether they need it or not, the system watches sensors in real time and says "this component needs attention soon." It was tested on real aircraft fleets for six months, covering more than 12 different systems across two fleets.

By the numbers
700 million Euro per year
Estimated benefit to European aviation from condition-based maintenance
6 months
Duration of operational demonstration on real aircraft fleets
12+
Aircraft systems tested in operational demonstration
2
Different aircraft fleets used in demonstration
15
Consortium partners
7
Countries represented in consortium
24
Total project deliverables
The business problem

What needed solving

Airlines and MRO providers spend billions on fixed-interval maintenance — pulling aircraft out of service on schedule whether components actually need servicing or not. This leads to unnecessary downtime, wasted parts, and still doesn't prevent surprise failures that ground planes unexpectedly. The European aviation industry loses an estimated 700 million Euro per year that could be saved by switching to maintenance based on actual component condition.

The solution

What was built

ReMAP built an open-source Integrated Fleet Health Management system that combines sensor data, machine-learning diagnostics, physics-based prognostics, and adaptive maintenance scheduling. Concrete outputs include an SHM data repository for structural health monitoring test data, validated algorithms for both systems and structural health prognostics, and a maintenance optimization process tested across more than 12 systems on two real aircraft fleets over 6 months.

Audience

Who needs this

Airlines with large fleets seeking to reduce maintenance costs and unscheduled groundingsMRO providers wanting to offer predictive maintenance servicesAerospace sensor and edge computing companies looking for validated aviation use casesAircraft manufacturers integrating health monitoring into next-generation platformsAviation regulators and certification bodies developing CBM standards
Business applications

Who can put this to work

Commercial Aviation
enterprise
Target: Airlines and fleet operators

If you are an airline dealing with costly scheduled maintenance downtime and surprise aircraft-on-ground events — this project developed an Integrated Fleet Health Management system that replaces fixed-interval inspections with condition-based maintenance. It was demonstrated across more than 12 systems on two different aircraft fleets over 6 months. The estimated benefit to European aviation is more than 700 million Euro per year from reduced maintenance costs and increased aircraft availability.

Aerospace MRO Services
mid-size
Target: Maintenance, Repair and Overhaul providers

If you are an MRO provider struggling to optimize maintenance scheduling and reduce unplanned repair events — ReMAP developed health diagnostics and prognostics using machine-learning techniques and physics models that predict when aircraft components actually need servicing. The system covers both structural and systems health monitoring. With 9 industry partners in the consortium, the solution was designed with real operational constraints in mind.

Aerospace Sensing and Monitoring
SME
Target: Sensor and edge computing technology companies

If you are a sensor technology or edge computing company looking for validated aviation applications — ReMAP matured promising sensing solutions for aircraft structures and leveraged existing aircraft sensors for systems monitoring. The project produced 24 deliverables including an SHM data repository, and addressed certification requirements for condition-based maintenance. The consortium spans 7 countries with 15 partners providing a ready-made network for commercialization.

Frequently asked

Quick answers

What would it cost to implement this system on our fleet?

The project data does not include specific implementation pricing. However, the objective states the estimated benefit to European aviation is more than 700 million Euro per year from reduced maintenance costs and increased availability. Actual implementation costs would depend on fleet size, aircraft type, and existing sensor infrastructure.

Has this been tested at industrial scale?

Yes — ReMAP conducted a 6-month operational demonstration involving more than 12 systems from two different aircraft fleets. This is described as unprecedented in scale for this type of condition-based maintenance validation. The consortium includes 9 industry partners across 7 countries.

What is the IP and licensing situation?

The project objective describes the Integrated Fleet Health Management solution as open-source. Specific licensing terms for individual components and the SHM data repository would need to be discussed with the consortium, led by Technische Universiteit Delft.

Does this meet aviation safety and certification requirements?

ReMAP specifically addressed safety risk assessment and certification challenges for condition-based maintenance. One of the four main goals was to perform safety risk assessment and promote concrete actions towards CBM certification. Based on available project data, a common roadmap towards CBM certification was defined.

How long would it take to integrate with our existing maintenance systems?

Based on available project data, the system was designed to leverage existing aircraft sensors for systems monitoring, which suggests integration with current infrastructure was a design priority. The 6-month operational demonstration provides validated integration experience. Specific timelines would depend on your fleet configuration and current maintenance management systems.

What types of aircraft components does this cover?

The system covers both aircraft systems and structures. For systems, it leverages existing aircraft sensors. For structures, it uses matured sensing solutions including structural health monitoring for composite subcomponents subjected to variable fatigue loading. More than 12 different systems were included in the demonstration.

Consortium

Who built it

The ReMAP consortium is notably industry-heavy at 60% (9 out of 15 partners), which signals strong commercial intent rather than purely academic research. The partnership spans 7 countries (CH, EL, ES, FR, IE, NL, PT), led by TU Delft in the Netherlands — one of Europe's top aerospace engineering universities. With 4 universities and 2 research organizations providing the science, and 3 SMEs among the industry partners, the consortium covers the full chain from sensor development to maintenance operations. This composition suggests the results are designed for real-world deployment, not just publications.

How to reach the team

Technische Universiteit Delft, Netherlands — aerospace engineering department

Order a report on this consortiumSee TECHNISCHE UNIVERSITEIT DELFT profile →
Next steps

Talk to the team behind this work.

Want to connect with the ReMAP team about implementing condition-based maintenance for your fleet? SciTransfer can arrange an introduction and help you evaluate fit.

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