AerSale Bets Big on Widebody Aircraft with Massive Florida MRO Expansion

HIALEAH GARDENS, FL – January 26, 2026 – AerSale Corporation has officially opened a new, 90,000-square-foot aerostructures MRO facility, a move that significantly expands its footprint in the global aviation aftermarket. The state-of-the-art center in Hialeah Gardens triples the capacity of its previous location and is strategically equipped to service large components from widebody aircraft, positioning the company to capture a larger share of a booming maintenance, repair, and overhaul market.

The facility replaces AerSale’s former operation in Medley, Florida, and represents a major leap in the company's ability to handle complex structural repairs. This expansion is a direct response to the growing demand for maintenance on long-haul aircraft like the Boeing 777 and Airbus A330, including their powerful GE90 and Rolls-Royce Trent engine nacelles and thrust reversers.

A Strategic Play in a Surging Market

The timing of AerSale's expansion aligns with powerful trends shaping the global aviation industry. With the aftermarket sector projected to reach nearly $90 billion by 2025, the demand for reliable and efficient MRO services has never been higher. This growth is fueled by an aging global fleet that requires more intensive maintenance and slower-than-expected deliveries of new aircraft, forcing airlines to extend the operational life of their existing widebody jets.

AerSale's investment targets the most complex and valuable segments of this market. The ability to service large aerostructures, particularly engine nacelles and thrust reversers for platforms like the Rolls-Royce Trent family—which powers a significant portion of the world's Airbus A330, A350, and Boeing 787 fleets—is a critical differentiator. These components are not only large but are often made of advanced composite materials requiring specialized repair techniques and equipment. The new facility's capabilities are engineered to meet these exacting standards, reducing aircraft-on-ground (AOG) time for operators.

“This new facility represents a quantum leap for AerSale’s Aerostructures MRO business,” said Nicolas Finazzo, Chairman and Chief Executive Officer at AerSale, in a statement. “By investing in additional space and advanced equipment, we are expanding our capacity, improving reliability, and positioning ourselves to better support our customers’ evolving fleet and operational needs.”

Fortifying South Florida’s Aviation Hub Status

The choice of Hialeah Gardens is no coincidence. Nestled between Miami International Airport (MIA) and Fort Lauderdale-Hollywood International Airport (FLL), the location offers unparalleled logistical advantages for airlines and leasing companies operating throughout the Americas. This strategic positioning is crucial in a region that has become a hotbed for aviation services.

South Florida's MRO sector is intensely competitive, with major players continuously investing to expand their capabilities. AAR Corp., for example, is expanding its own Miami airframe MRO facility, while AeroRepair recently tripled its capacity by relocating to a larger site in Hialeah Gardens. AerSale's move not only keeps pace but aims to set a new standard for specialized aerostructure repair, turning Hialeah Gardens into a growing cluster for high-tech MRO services.

By focusing on widebody components, AerSale carves out a vital niche, strengthening its competitive posture against both regional specialists and global MRO giants. The expansion is part of a broader consolidation of AerSale’s presence in the region, following its corporate headquarters relocation to nearby Doral in late 2024, signaling a deep commitment to the South Florida aviation ecosystem.

Inside the State-of-the-Art Operation

The Hialeah Gardens facility is more than just a larger building; it is a ground-up redesign of the MRO workflow. The company has invested in what it calls "state-of-the-art infrastructure," including redundant heavy equipment to maximize uptime and throughput. The installation of duplicate 40-foot paint booths and 40-foot heating ovens ensures that a single point of failure will not derail tight customer schedules.

At the heart of the new operation are its advanced composite repair capabilities. The facility includes environmentally controlled clean rooms and a 10' x 20' automated autoclave, allowing for OEM-equivalent repairs on materials like carbon fiber, Kevlar, and honeycomb structures. These materials are integral to modern thrust reversers and nacelles, which must be repaired with surgical precision to maintain structural integrity and aerodynamic performance.

This technological investment is designed to translate directly into customer benefits. By streamlining the repair process, from sanding to painting to curing, AerSale aims to deliver faster and more consistent turn-around times—a critical metric for airlines looking to maximize fleet utilization and minimize costly downtime. The enhanced capacity and redundant systems are built to provide a level of reliability that customers in the high-stakes aviation industry demand.

An Investment in Future Growth

Financially, the Hialeah Gardens facility is a cornerstone of AerSale's growth strategy. With revenues of $345.1 million in 2024, the company is making a significant capital investment to secure high-value, long-term contracts in the lucrative widebody aftermarket. Analysts see this as a calculated scalability play, designed to monetize the increased physical capacity by attracting new airline and lessor clients who operate the world's largest aircraft.

The economic impact extends to the local community as well. While specific job numbers have not been released, an expansion of this magnitude inherently creates skilled technical and administrative positions, contributing to the local economy. The investment injects significant capital into Hialeah Gardens and reinforces the region's reputation as a world-class center for aviation and logistics.

As the aviation industry continues to evolve, the need for integrated, technologically advanced MRO solutions will only grow. With its new Hialeah Gardens facility, AerSale is not just expanding its floor space; it is building a platform for future growth and solidifying its role as a key partner for airlines navigating the complexities of modern fleet management.