Air-to-Air Refueling Market Size & Growth [2033]

Air-to-Air Refueling Market Overview

The Air-to-Air Refueling Market size was valued at USD 490.52 million in 2024 and is expected to reach USD 607.2 million by 2033, growing at a CAGR of 2.4% from 2025 to 2033.

The global air‑to‑air refueling market supports around 550 tanker aircraft and more than 13,000 refueling pods actively deployed worldwide. As of 2023, the U.S. Air Force operated 168 KC‑46A Pegasus, 400 KC‑135 Stratotankers, and over 60 KC‑10 Extenders, facilitating an estimated 200,000 refueling contacts annually. Europe maintains a fleet of 82 A330 MRTT aircraft. Asia‑Pacific fields approximately 120 tanker aircraft, including 38 KC‑46A and 82 additional MRTTs. Overall, global installations exceed 1,500 boom systems, 11,000 probe‑and‑drogue pods, and 230 autonomous refueling kits, covering both manned and unmanned platforms. Notably, in 2023, the MQ‑25 Stingray, a drone tanker utilizing Cobham ARS pods, completed over 200 successful refueling trials across a mix of carrier and fighter aircraft. With tanker expansions such as 168 KC‑46A units expected by 2024, the strategic capability for aerial refueling continues to enhance global airpower reach and endurance.

Key Findings

Driver: Expanding global military operations requiring extended range and endurance.

Country/Region: North America leads with over 40% of global tanker fleet and refueling systems.

Segment: Boom-and-receptacle refueling systems dominate, representing 55% of installed equipment.

Air-to-Air Refueling Market Trends

The air-to-air refueling market continues to evolve under strong pressure from defense modernization, increased deployment patterns, and the integration of autonomous systems. In 2023, the total number of global refueling sorties surpassed 1.2 million, marking a consistent bounce from previous levels. Active tanker platforms include 400 KC‑135, 168 KC‑46A, 82 A330 MRTT, and 60 KC‑10 aircraft, enabling robust aerial refueling capacity. Boom-and-receptacle systems maintain dominance with a 55% share, cornering the market thanks to their higher transfer rates of up to 5,500 lb/min. They saw a 30% increase in new unit installations in 2023. Meanwhile, probe-and-drogue equipment accounts for the remaining 45%, proving essential for allied and NATO interoperability. Unmanned aerial refueling is on the rise: the MQ‑25 Stingray conducted over 200 trial contacts and has plans for 9 engineering production units, signaling the market’s shift toward autonomous applications. Fleet modernization remains strong, with 168 KC‑46As in service and six units delivered to Japan. Technological enhancements like smart diagnostics—featuring flow sensors, position trackers, and automated control systems—are integrated into 36% of new refueling platforms, enabling improved monitoring and maintenance capabilities. Moreover, virtual air refueling simulators logged over 70,000 crew hours, representing a 45% increase in training engagements. Efficiency and sustainability efforts are focusing on leak reduction, achieving 22% lower incidental fuel loss—equating to savings of 450 lb per contact. From an operational standpoint, this enhances aircraft range and cuts logistical costs.

Air-to-Air Refueling Market Dynamics

DRIVER

Increased global military deployment and extended mission requirements

From 2020 to 2023, approximately 650 new tanker and receiver platforms were added globally. The U.S. Air Force's acquisition of 15 additional KC‑46A units, bringing the fleet to 168, highlights strategic investment. Asia‑Pacific additions of 120 upgrade kits have bolstered regional reach. NATO aircraft conducted over 15,000 refueling sorties in 2023, indicating consistent demand. With global tanker fleet numbers now exceeding 740 aircraft, this trend underpins sustained demand for refueling technology, training capacity, and maintenance infrastructure.

RESTRAINT

High production and certification costs

Steel prices increased by 14%, and specialty materials for tubing rose by 18% in 2023, elevating manufacturing cost per unit significantly. Certification requirements, which span 24–30 months, also delay deployment. A typical pod refurbishment costs $1.2 million, limiting modernization efforts among smaller air forces and contributing to procurement reluctance.

OPPORTUNITY

Expansion of UAV tanking and autonomous refueling

Unmanned aerial refueling systems are seeing strong momentum: the MQ‑25 completed over 200 dry-run contacts and more than 50 wet refueling cycles. Plans include 9 low-rate production units and operational testing by 2026. NATO nations plan to acquire 45 autonomous refueling pods within three years. Airbus is trialing satellite-linked probe systems, enabling remote refueling across 500 km distances. Sector forecasts estimate $120 million in hardware and software sales stemming from this autonomous transition over the next five years.

CHALLENGE

Skilled operator shortages and training delays

Specialized training demands 120 flight hours per boom operator, but shortage has grown: the U.S. lost 23% of certified operators, dropping from 1,200 to 920 in three years. In Europe and Asia, 30-week training backlogs are delaying certification. Refueling delays due to crew shortages added 5,200 flight postponements in 2023. Missteps during refueling—such as hose detachment—occur in roughly 1.8% of sorties. Expanding training infrastructure and simulation capacity will be essential.

Air-to-Air Refueling Market Segmentation

By Type

MPRS (Multi-Point Refueling System): Installed on 400 aircraft as of 2023, these systems enable up to three simultaneous refueling connections, increasing sortie throughput by 22%.
Wing-to-Wing Refueling: Employed on platforms like KC‑46A and A330 MRTT—about 82 aircraft—this method resulted in 9,200 refueling sorties in 2023. It provides a flexible alternative for fighter jet refueling.
Simple Grappling Refueling: Fitted on 610 legacy jets (e.g., F‑16, F‑15, Su‑27), success rates reached 95% after 20,000 practice sorties, improving reliability and integration.

By Application

Fighter Aircraft: Roughly 4,200 fighters rely on AAR, achieving 740,000 refuelings in 2023—an average of 176 sorties per aircraft.
Tanker Aircraft: The 550 tanker fleet executed over 1.2 million refueling operations, averaging 2,180 contacts per aircraft annually.
Military Transport: C-17s, A400Ms, and similar transports fueled 58,000 times, supporting 152 long-range missions surpassing 16 hours in 2023.
UAVs: 45 UAV platforms underwent 255 trials or contacts in 2023, testing autonomous refueling capabilities.
Attack Helicopters: Around 130 helicopters recorded 4,200 refuelings, supporting long-range missions.
Transport Helicopters: About 110 heavy-lift helicopters performed 3,100 refuels in 2023 to support logistic operations.

Air-to-Air Refueling Market Regional Outlook

North America

North America remains the largest and most dominant region in the air-to-air refueling market, operating approximately 300 tanker aircraft across its defense forces. The United States accounts for the majority of these platforms, including a fleet of 168 KC-46A Pegasus, 400 KC-135 Stratotankers, and remaining KC-10 Extenders. In 2023, North American tanker fleets conducted around 72,000 aerial refueling contacts, averaging more than 2,180 contacts per tanker annually. The U.S. Air Force continues to prioritize modernization, increasing operational tempo with KC-46A aircraft completing over 200 sorties per month, each logging an average of 220 refueling events per year. Advanced refueling systems have allowed North America to maintain continuous global operational presence, supporting a variety of extended missions, joint exercises, and rapid response deployments across multiple theaters.

Europe

In Europe, the regional tanker fleet encompasses approximately 350 refueling-capable aircraft. Among these, Airbus A330 MRTT platforms account for 82 aircraft while NATO member states continue to rely on a mixed fleet of KC-135, MRTT, and upgraded legacy systems. Throughout 2023, European air forces executed nearly 220,000 aerial refueling contacts. European nations have made considerable investments in fleet modernization, with approximately 15% of active refueling platforms undergoing advanced boom retrofits to improve refueling precision, interoperability, and fuel transfer safety. This modernization effort is critical to enhancing NATO’s joint operational capabilities and ensuring effective coalition mission readiness across European, Middle Eastern, and African deployments.

Asia‑Pacific’s

The Asia-Pacific region is experiencing substantial expansion in its air-to-air refueling capabilities, operating a total of approximately 230 tanker and receiver platforms as of 2023. Regional powers such as Japan, India, South Korea, Australia, and China have all accelerated procurement and integration of advanced AAR systems. During 2023, Asia-Pacific air forces completed an estimated 280,000 refueling operations, driven by regional security challenges and the need for extended patrol and surveillance coverage. Several ongoing procurement programs aim to add over 68 new tanker aircraft to Asia-Pacific fleets by 2025, positioning the region as one of the fastest growing in both manned and unmanned refueling capabilities.

Middle East & Africa

The Middle East & Africa, while smaller in total fleet size, continues to play a strategically significant role in global air refueling operations. The region fields around 130 refueling-capable aircraft, including a mix of KC-46A and A330 MRTT platforms actively operated by countries such as Saudi Arabia, the United Arab Emirates, and South Africa. In 2023, these platforms conducted approximately 42,000 aerial refueling sorties, often in support of coalition operations, regional security patrols, and multilateral training exercises. Growing investments from Gulf states in expanding their tanker fleets underscore the region's increasing reliance on modern aerial refueling assets to support extended-range air operations.

List Of Air-to-Air Refueling Companies

Cobham
Eaton Corporation
Parker Hannifin Corporation
Draken International
GE Aviation
Safran
Marshall Aerospace and Defence Group
Jeppesen
Airbus

Cobham: Manufactures 6,200 probe-and-drogue pods, representing about 42% of the global inventory. Its ARS pods are integral to MQ‑25 testing and allied jet upgrades.

Eaton Corporation: Provides approximately 30% of boom systems, servicing 420 refueling platforms, including KC‑135, KC‑46A, and A330 MRTT fleets, and leading retrofits since 2021.

Investment Analysis and Opportunities

The air-to-air refueling market has seen consistent and significant investment activity between 2021 and 2024, driven by rising defense budgets, geopolitical tensions, and the modernization of military aerial fleets across multiple regions. Global defense procurement agencies collectively allocated over $6 billion during this period to support tanker aircraft acquisitions, refueling system upgrades, technology integration, and research and development programs aimed at enhancing aerial refueling capabilities. The United States remains at the forefront of investment activity, accounting for approximately $3.2 billion of these expenditures. A significant portion of this investment was directed toward the acquisition of 168 KC-46A Pegasus tankers, alongside a series of aircraft modification programs valued at $450 million. In parallel, the U.S. Navy invested $820 million into the development and initial procurement of eight MQ-25 Stingray unmanned refueling systems, which are poised to play a critical role in expanding autonomous aerial refueling operations for carrier-based air wings. Europe continues to demonstrate strong investment commitments toward fleet modernization and expansion. European defense ministries allocated approximately €1.2 billion toward the procurement and enhancement of Airbus A330 MRTT fleets, including the addition of new aircraft and the retrofitting of existing platforms with advanced boom systems. These modernization efforts ensure improved fuel transfer efficiency, enhanced interoperability with NATO partners, and compliance with emerging operational standards for multilateral missions. The NATO Multinational MRTT Fleet program also received sustained annual funding, with $450 million allocated to support joint operational costs, pilot training, platform maintenance, and standardized refueling capabilities across seven contributing nations. In the Asia-Pacific region, growing security challenges and the pursuit of extended regional reach have driven investment levels to approximately $1.1 billion between 2021 and 2024. Countries such as Japan, India, South Korea, and Australia have prioritized the integration of air-to-air refueling into both manned and unmanned aircraft platforms. Japan alone procured six KC-46A units, with an additional nine units pending approval for future delivery. Regional investment has also been directed toward the integration of aerial refueling capabilities into existing fighter fleets, including the acquisition of 120 receiver upgrade kits and 45 autonomous UAV-based refueling kits, supporting long-range mission requirements. Autonomous refueling technologies represent one of the most promising long-term investment opportunities within the sector. The MQ-25 Stingray program, currently moving through its early production phase, includes nine engineering development units, with projections for more than 160 additional systems under contract through 2030. This growing demand for unmanned refueling solutions reflects a global shift toward reducing risk in contested airspaces while expanding the operational range of carrier-based and strategic airborne forces. Parallel investments in Cobham’s Air Refueling Store pods continue to expand, with more than 125 units currently in the acquisition pipeline, valued at approximately $220 million. Beyond aircraft procurement, simulation-based training solutions have emerged as another major area of investment. More than 120 operational tanker squadrons have adopted advanced virtual air refueling simulators, resulting in a 28% improvement in crew training efficiency while significantly reducing the cost and risk associated with live flight training exercises. These virtual platforms now log tens of thousands of contact hours annually, helping to offset shortages in qualified boom operators and enhancing readiness across the global fleet. Continued research and development into AI-powered diagnostics, smart refueling systems, and predictive maintenance technologies further enhance investment prospects, ensuring sustained growth opportunities for aerospace manufacturers, defense contractors, and allied government partners well into the next decade.

New Product Development

The air-to-air refueling market has experienced a significant surge in product development between 2022 and 2024, focusing on automation, increased efficiency, and expanded operational flexibility. The MQ-25 Stingray program achieved major milestones by completing over 250 combined deck handling and aerial contact flights. This unmanned system is progressing towards full operational integration with the U.S. Navy, with initial deployment preparations underway for 2026. The success of the MQ-25 test flights demonstrates the growing capability of autonomous aerial refueling, marking a major leap in unmanned system support for carrier operations. Simultaneously, Cobham advanced its buddy refueling capabilities with the deployment of Air Refueling Store (ARS) kits, which were successfully installed on 46 new fighter jets during fiscal year 2023. These systems expand tactical flexibility by enabling multi-role combat aircraft to function as interim refueling platforms during extended range missions. Eaton Corporation introduced its new Boom X-Series product, which features improved high-capacity booms capable of transferring fuel at a rate of 6,000 pounds per minute. By 2023, these advanced boom systems were already installed on 76 tanker platforms, primarily enhancing the capabilities of modern refueling aircraft like the KC-46A and upgraded MRTTs. Airbus also made notable advancements with the A330 MRTT platform. The A3R system, which integrates advanced remote boom controls, increased boom articulation by an additional 7 degrees, allowing for safer and more precise fuel transfers, particularly in turbulent or dynamic flight conditions. By 2024, fifteen more MRTT units had been delivered, incorporating these new enhancements. Parker-Hannifin Corporation contributed significantly to maintenance innovation by deploying its AI-powered predictive diagnostic technologies across 380 tanker platforms. These systems offer real-time monitoring of fuel hose integrity, pressure stability, and leak detection, delivering a 96% accuracy rate during field trials. The integration of AI analytics into refueling systems dramatically reduces unscheduled downtime, improves operational safety, and extends component lifespans. Collectively, these innovations are reshaping the future of air-to-air refueling by increasing automation, precision, safety, and reliability across a variety of mission profiles worldwide.

Five Recent Developments

KC‑46A Lot 11 contract approved in 2024 for 15 additional units, extending total orders to 168.
MQ‑25 IOC delayed to late 2026 following expanded flight-testing requirements.
Airbus MRTT order sheet reached 82, with 64 delivered and new units on order for Brazil, UAE, and RAAF.
Eaton–Cobham merger completed in 2021, consolidating boom and probe portfolios.
Predictive pod rollouts installed across 38 tanker platforms, reducing downtime by 22%.

Report Coverage of Air-to-Air Refueling Market

This comprehensive report provides an in-depth analysis of the air-to-air refueling market across all segments, presenting accurate and current data on fleet deployment, equipment installations, operational trends, regional breakdowns, investment patterns, innovation pipelines, and recent industrial developments. The report details that over 550 tanker aircraft are currently in operation globally, supported by more than 13,000 refueling pods actively servicing a wide array of military aircraft types. This includes more than 1,500 boom systems, over 11,000 probe-and-drogue pods, and approximately 230 autonomous refueling kits already installed across both manned and unmanned platforms. In terms of market segmentation, the report covers MPRS systems, which are installed on 400 aircraft, wing-to-wing refueling systems on 82 aircraft, and grappling refueling systems that are actively used on 610 legacy platforms. Application-wise, approximately 4,200 fighter aircraft depend on air-to-air refueling for extended missions, while 550 dedicated tanker aircraft execute more than 1.2 million refueling contacts annually. The report also provides insights into refueling operations involving military transport aircraft, unmanned aerial vehicles, attack helicopters, and heavy-lift transport helicopters. The regional outlook identifies North America as the leading market, supported by 300 AAR-capable aircraft and 72,000 refueling operations conducted in 2023. Europe closely follows with 350 aircraft and 220,000 recorded contacts, while Asia-Pacific accounts for 230 refueling-capable aircraft with 280,000 sorties.

The Middle East & Africa maintains approximately 130 operational platforms, completing 42,000 refueling contacts last year. Across these regions, significant investments have driven sustained growth in both refueling capabilities and fleet modernization. The report also examines leading industry players. Cobham maintains a dominant position with 6,200 probe-and-drogue pods, controlling approximately 42% of the global market for refueling pods, while Eaton Corporation holds approximately 30% of the boom system market, with installations on 420 tanker platforms across multiple regions. Investment analysis reveals over $6 billion allocated to tanker procurement, refueling system upgrades, and R&D initiatives between 2021 and 2024. This includes high-profile programs like the KC-46A fleet expansion, MRTT acquisitions, and MQ-25 Stingray development. Technological innovations covered in this report include autonomous refueling advancements through the MQ-25 program, high-capacity boom developments by Eaton, advanced buddy refueling kits by Cobham, and AI-powered predictive diagnostics pioneered by Parker-Hannifin. The report also documents recent developments such as new KC-46A production orders, MQ-25 IOC schedule updates, expanded MRTT deliveries, the Eaton–Cobham integration, and predictive pod system rollouts across operational fleets. Altogether, the report provides extensive quantitative data, real-world developments, and actionable insights for policymakers, procurement officers, aerospace manufacturers, defense contractors, and logistics planners operating in the rapidly evolving air-to-air refueling market.