Market Sizing & Segmentation for Aircraft Engine Coatings
A multi-billion-dollar coatings & technology firm faced a critical challenge: estimating actual coatings consumption per aircraft engine model. While top-level market reports existed, translating production and MRO visit data into real-world coating demand required a bottom-up model grounded in engineering insight, data analytics, and industry know-how.
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Chuck led the development of this model, leveraging design engineering principles, industry knowledge, and tools like Excel, Power BI, and Python. We accounted for complex variables—such as engine architecture, bypass ratios, and component geometry—to build scalable models for turbofan and turboprop engines. By scaling actual surface area data from reference engines and applying correction factors for thrust class, fan diameter, and spool count, we estimated coating coverage by engine model.
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Beyond geometry, we layered in application efficiency (factoring material loss during coating processes) and MRO practices (e.g., partial recoating vs. full strip-and-recoat by engine section). This enabled realistic, scenario-based coating demand forecasts across both OEM production and aftermarket sectors.
The result was a robust, flexible market model visualized through an interactive Power BI dashboard. It provided segment-specific insights by engine type, OEM, and coating class, and allowed strategic scenario testing. This work gave the firm a competitive edge and a dynamic platform for long-term market planning.
