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After years of crisis caused by the COVID-19 pandemic, the aviation industry is returning to global growth. Data shows that in 2024, according to IATA forecasts, the number of passengers will reach 4.96 billion, almost completely returning to 2019 levels. At the same time, airline profits are expected to reach $30.5 billion, which is a strong signal of the sector’s recovery. This means one thing: aviation has not only survived, but is regaining its importance as a driver of global mobility, trade and innovation.

In this extremely dynamic reality, those involved in the industry – especially manufacturing – should focus on hard data.

Airbus’ forecast predicts that by 2042, the number of commercial aircraft worldwide will double to 40,000. This means a huge increase in demand for components, technologies, supply chains and, crucially, energy resources and raw materials.

However, it is not only the numbers that capture the imagination. It is also the challenges facing the industry. In 2023, aviation accounted for approximately 2.5% of global energy-related CO₂ emissions, according to data from the International Energy Agency. This may seem relatively small, but in the context of growing demand and ambitious climate targets, it is becoming one of the fundamental topics of debate.

“We are at a point where we need to balance the growing global demand for flights with the reduction of emissions. This complex challenge requires not only technological progress, but also a commitment to operational efficiency and development work on alternative fuels” – Jan Florian, President and Chief Operating Officer of MTU Aero Engines Polska

This statement sums up the direction in which the industry is heading. Innovations such as electric, hybrid and hydrogen propulsion are no longer a futuristic vision – they are concrete research and development projects being implemented by market leaders. The goal is not only to reduce CO₂ emissions, but also to reduce noise and improve energy efficiency.

For companies operating in the manufacturing sector, this opens up a window of opportunity. On the one hand, there is growing demand for aviation infrastructure and technologies, and on the other, the need to adapt to stringent climate standards.

Through the Fly the Green Deal initiative, Europe is aiming to reduce greenhouse gas emissions by 55% by 2030 and achieve climate neutrality by 2050, in the spirit of the European Green Deal. What is more, future regulations will not be limited to CO₂ emissions – they will also cover nitrogen oxides, water vapour and contrails, forcing a new approach to aircraft design and operation.

From a manufacturing perspective, this means a revolution – literally. From manufacturing components from low-emission materials, to introducing digital twins in product lifecycle management, to developing infrastructure for alternative energy sources, the industry today faces a challenge and opportunity on a scale comparable to the dawn of the jet age.

MTU Aero Engines and the CLAIRE initiative

Faced with these changing market realities, stricter environmental regulations and social expectations regarding climate neutrality, the aviation sector is facing both a challenge and an opportunity.

An example of adapting to reality is the actions of MTU Aero Engines, which is implementing CLAIRE (Clean Air Engine) – a programme that is directly in line with current trends in energy and industrial transformation.

For manufacturing companies operating in the advanced technology sector, CLAIRE is an example of a model approach to process and product innovation based on measurable environmental and technological goals.

Stages of transformation: a technological roadmap to neutrality

The CLAIRE initiative has been divided into three main technological stages, each reflecting a successive level of advancement and complexity:

Stage I: Geared Turbofan (GTF) + SAF (sustainable fuels)

The GTF engine currently in use, available since 2016, combined with sustainable aviation fuels (SAF), allows for a real reduction in CO₂ emissions of up to 80% over the life cycle.

Importantly, as Marcin Pietrzak, Director of Engineering and Technology at MTU Aero Engines Polska, points out:

‘Tests have shown that SAF is fully compatible with existing engines, which allows for its immediate implementation. As the production technology matures, we also anticipate a decrease in unit costs, which may significantly increase the rate of adoption by airlines.”

For engineers and technologists in the industry, this means the possibility of integrating new materials, components resistant to differences in fuel chemistry, and the development of combustion monitoring systems to optimise NOₓ emissions.

Stage II: Flying Fuel Cell™ and new generation GTF

The planned development of a new generation of GTF engines between 2030 and 2040 and the introduction of the Flying Fuel Cell™ (FFC) system is a milestone. The hydrogen-based fuel cell system, which powers an electric motor, will emit only water vapour, eliminating greenhouse gas and nitrogen oxide emissions.

It is worth noting that a 1.2 MW FFC technology demonstrator under the EU’s HEROPS programme will be ready by 2035. The system has been optimised for weight and integration with regional aircraft platforms.

“As an aviation company, we are open to new technologies, especially when technologies such as FFC have enormous potential to contribute to the sustainable development of aviation. The revolutionary Flying Fuel Cell concept is a solution designed from scratch and strictly for the aviation industry, and I am always proud to emphasise that most of the design work is carried out at MTU Aero Engines Polska” – Marcin Pietrzak, Director of Engineering and Technology at MTU Aero Engines Polska

Stage III: Zero emissions by 2050

The third stage, planned for 2050, involves the full integration of hydrogen systems into short and medium-haul routes and the implementation of exhaust gas heat recovery technology. This requires innovative engineering solutions in the fields of materials science, cooling systems and new-generation turbines.

Data and strategic objectives

According to IATA estimates, achieving climate neutrality by 2050 will require:

a 65% reduction in CO₂ emissions through SAF
the introduction of alternative propulsion systems (e.g. fuel cells, electric propulsion)
operational and logistical optimisation (approximately 10-15% potential reduction)

For component manufacturers, this means shifting investment towards advanced composite materials, precision fuel systems, and digital twins that enable continuous simulation of propulsion performance.

Cooperation as a prerequisite for success

The transformation will not be possible without effective cooperation between industry, science, regulators and operators.

This necessity is also emphasised by Jan Florian, President of MTU Aero Engines Polska:

‘Investing in technologies such as Flying Fuel Cell is not only a response to climate pressure. It is a strategic step towards global competitiveness, allowing companies to stay ahead of regulations and shape the future of the market.’

Programmes such as HEROPS (Hydrogen-Electric Zero Emission Propulsion System) create new opportunities for cooperation between manufacturing companies – both those supplying mechanical components and software control systems or solutions for the Industrial Internet of Things (IIoT).

The programme aims to create a scalable hydrogen-powered electric drive for regional aircraft by 2035, with a 1.2-megawatt ground demonstrator as part of the Flying Fuel Cell™ technology development.

For manufacturing plants, both in Europe and beyond, the CLAIRE programme and its components (GTF, SAF, FFC, HEROPS) mean:

the need to transform production lines – adapting to new materials and fuel cell designs
increased demand for precision machining technologies and new quality standards
integration of digital simulation tools for testing and monitoring environmental impact
growing importance of automation and production flexibility – key to changing regulatory and technological requirements

Summary

The measures taken by MTU Aero Engines are not only an environmental strategy, but a comprehensive roadmap for the development of the industry in the coming decades.

If the future of aviation is to be green, industrial production – digital, agile and precise – will be its driving force.

The development of modern technologies and alternative fuels is an essential element for the sustainable development of the aviation industry and environmental protection. In the face of growing challenges related to CO₂ and NO_x emissions and climate change, innovation in this area is becoming essential.

“Programmes such as HEROPS and FFC are excellent examples of measures aimed at reducing the environmental impact of aviation. Flying Fuel Cell is a hydrogen-powered engine that emits only water vapour, significantly reducing the environmental impact of aviation. Investing in such technologies not only helps to achieve sustainable development goals, but also strengthens the competitiveness of aviation companies in the global market. In the long term, such innovations can contribute to a more environmentally friendly and sustainable aviation industry, which is beneficial for both the environment and the economy,” concludes Jan Florian, CEO of MTU Aero Engines Polska.