Sustainable Practices for Aircraft Decommissioning and Recycling in a Circular Aviation Economy

The aviation industry requires a series of actions that will transform its current status, aiming for sustainable operations. Aviation’s end-of-life stream is a pivotal lever for circularity, yet current dismantling and recycling practices leave significant value unrealized. Circular Economy could be considered as a transformational approach to the aviation industry and address its environmental and economic challenges, meeting sustainability principles. This study conducts a PRISMA-guided qualitative systematic review across academic and industry sources to synthesize regulations, technologies, and economics of aircraft decommissioning. It aims to quantify material recovery potential and environmental gains at the aircraft level and assess technology readiness and cost drivers for metals, polymers, and composites. Findings indicate that optimized decommissioning enables high-value part reuse and substantial material recovery (notably aluminum), with associated lifecycle greenhouse-gas avoidance at the aircraft scale. However, high costs, weak regulations, and limited recycling technologies hinder adoption. Results show that optimized dismantling and certified part-reuse pathways can recover up to 85–90% of total aircraft mass, with potential CO2-emission avoidance of 25–35 t per narrow-body aircraft compared with landfill disposal. Metal recycling technologies (TRL 8–9) already achieve high yields, whereas polymer and composite recycling remain limited (TRL 5–6) by purity and certification barriers. A comparative assessment of EU, US, and Asia–Pacific regulations identifies enforcement and infrastructure gaps hindering implementation. The study introduces an integrated CE roadmap for aviation comprising (i) standards-aligned design-for-disassembly and digital traceability, (ii) accredited MRO-to-reuse networks, and (iii) performance-based policy incentives.