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FEATURE BEARINGS, SEALS & GASKETS examining the role of miniature


bearings in aircraft maintenance


such as turbines, compressors and gearboxes. While miniature bearings themselves are


Chris Johnson, managing director of SMB


Bearings, explains why prioritising precision miniature bearings could enhance the quality and cost-effectiveness of aircraft maintenance


T


here are a couple of major issues faced when it comes to aircraft maintenance. For a


start, ageing aircraft require more frequent and complex maintenance, which puts greater pressure on Maintenance, Repair and Overhaul (MRO) operations. At the same time, however, airline maintenance performance has worsened across several key operational metrics. According to Boston Consulting


Group (BCG), technical dispatch reliability has declined by as much as 50% in some cases, reducing the likelihood that aircraft are ready for scheduled departures. But, maintenance-related delays have increased significantly, in some cases occurring two to three times more frequently than before. While these issues do not affect


operational safety, the costs of deteriorated performance include lost revenue and higher compensation costs. Maintenance delays are also putting extra strain on aircraft components. More effective aircraft maintenance means


reducing time spent on administrative tasks, freeing experienced workers to perform actual maintenance activities, as well as training and supervision. Furthermore, predictive maintenance encourages more accurate forward planning to avoid delays. Much has already been written about


digitalisedmaintenance, but companies are turning increasingly towards artificial intelligence (AI). As an example, AI-based technical support can free human workers to focus on practical maintenance tasks. But, AI systems can be expensive and less compatible with older aircraft.


3 DESIGN SOLUTIONS MAY 2026 4


AI language models and predictive systems rely on freely accessible, relevant and high- quality data, so compatibility with modern Industry 4.0 systems is a must. Fortunately, this is where Industry 4.0


sensors can play a significant role, particularly when external sensors are positioned adjacent to precision miniature bearings to capture signals generated within surrounding rotating assemblies.


bearing applications Miniature bearings are increasingly being used in applications where precision, smooth rotation and low friction are essential for small and precise movements in applications including in aircraft. They play a key role in vital systems like flight control mechanisms, and engine parts


passive mechanical components without integrated sensing capability, they remain critical components within sensor-enabled systems around them. When in motion, precision bearings will generate a variety of physical signals such as micro-vibrations, heat, or even slight changes in shaft motion. These physical outputs then propagate throughout the machine body, where external sensors positioned near bearings can track key condition metrics produced by these signals such as temperature, vibration, load, strain, rotational speed and acoustic signatures. The data obtained can then be fed back to maintenance software, enabling earlier detection of potential failures, supporting predictive maintenance to reduce unexpected delays and improving MRO planning and operations. Aircraft components


operate under intense speeds and stress, which is why bearings used with these systems must be durable. To this end, ceramic bearings can handle high temperatures, corrosion and high speeds while still being lightweight. Stainless steel bearings, on the other hand, provide good fatigue strength and hardness as well as


corrosion resistance. When choosing bearings, material selection is guided by the specific demands placed on each component and application within the aircraft – large or small. By focusing on often overlooked aircraft


components and leveraging advances in AI, precision miniature bearings can deliver significant impact. These components play a critical role within condition-monitoring systems that generate the data used for predictive maintenance, helping reduce pressure on MRO operations and address one of the industry’s most complex challenges: rising maintenance costs.


SMB Bearings T: 01993 842555 www.smbbearings.com


www.designsolutionsmag.co.uk


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