Texas, a state long associated with innovation, industry, and aviation, is experiencing a rapid expansion of its aerospace sector. From defense manufacturing in Fort Worth to Houston’s historic role in space exploration, this growth is undeniable.

However, a significant and less apparent challenge looms: a shortage of skilled engineers and aviation maintenance technicians. This deficit poses a threat to the very progress Texas has diligently pursued.

According to Texas Economic Development Corporation, the state is home to more than 1,400 aerospace and aviation establishments. The report further notes that Texas has a “large and diverse talent pool of over 150,000 skilled workers” in aerospace/aviation — and produces nearly 11,000 aerospace- and aviation-related degrees annually. 

Nationally, while specific figures for engineers over 55 in the American Institute of Aeronautics and Astronautics (AIAA) membership are not publicly broken out in recent reports, the organization has repeatedly flagged an ageing workforce across aerospace engineering and related technical fields. For instance, the U.S. employment outlook for aerospace engineers lists about 71,600 jobs in 2024 and a projected job growth of 6 % through 2034. Combined, these indicators suggest that retirements are starting to outpace the pipeline of new entrants in the engineering side of aerospace.

Beyond engineers, a critical and often under-emphasized segment is the workforce of aircraft maintenance technicians (AMTs) and mechanics. Industry analyses show that the shortage of AMTs is acute:

  • The Aviation Technician Education Council (ATEC) and consultancy Oliver Wyman report that the U.S. civil commercial aviation maintenance workforce (both certificated and non-certified technicians) totals more than 431,000 personnel.

  • They forecast a 10% shortfall in certificated mechanics by 2025 just for the commercial air-transport segment — before accounting for business/general aviation.

  • One analysis projects that by 2034, about 416,000 new technicians will be needed globally (commercial plus business aviation) just to keep up with fleet growth and retirements, and that up to 83% of the existing technician workforce may retire or leave within the next ten years in some regions.

  • The U.S. Bureau of Labor Statistics (BLS) states for the occupation of “Aircraft and Avionics Equipment Mechanics and Technicians” that there are about 160,800 jobs in 2024, with projected growth of 5 % through 2034, and about 13,100 openings per year on average (largely driven by replacement needs).

These data underline that the pipeline of younger, qualified technical talent (both engineers and maintenance technicians) is not keeping pace with the demand being driven by ageing workforce, retirements, and fleet growth.

This workforce imbalance is already visible across Texas’s aerospace ecosystem. Manufacturers in Fort Worth, Dallas, and Houston are competing for the same small pool of qualified professionals — mechanical, systems, and electrical engineers who understand both the legacy technologies of traditional manufacturing and the digital tools driving the next era of aerospace design.

A Perfect Storm of Growth and Shortage

The current shortage didn’t happen overnight. Texas has become a magnet for aerospace expansion as companies reshore production and diversify supply chains closer to home. That growth, combined with the rapid adoption of automation, artificial intelligence, and digital twin technologies, has created a skills gap that traditional recruiting alone can’t close.In simple terms: The state is creating aerospace jobs faster than it can train engineers to fill them. Universities and trade programs are producing talented graduates, but many lack the hands-on experience or certifications required for complex, regulated environments like defense or space manufacturing.

The Cost of the Talent Gap

For aerospace companies, the shortage has tangible consequences. Project schedules stretch longer. Costs rise as firms compete for a limited number of licensed engineers. And as regulatory requirements from the FAA and DoD become more stringent, the need for specialized technical oversight grows even sharper.

These challenges aren’t unique to Texas, but their impact here is magnified because of the state’s scale and momentum. Texas ranks among the top five states for aerospace employment and continues to attract major investments in both commercial aviation and defense systems. That growth, while promising, requires intentional planning to ensure the workforce doesn’t become the constraint.

Building the Next Generation of Engineers

Addressing the talent shortage means thinking differently about how we cultivate and sustain our workforce. It’s not only about recruiting from other states — it’s about developing and retaining skilled professionals here in Texas. That starts with strengthening partnerships between industry, universities, and technical schools; expanding apprenticeship and mentorship programs; and creating environments where experienced professionals can pass their knowledge to the next generation before retiring.

Equally important is fostering greater cross-utilization between Aircraft Maintenance Technicians (AMTs) and engineers.

When these two disciplines work side-by-side, they bring together complementary skill sets — the technicians’ deep, hands-on understanding of aircraft systems and the engineers’ analytical and design expertise. This collaboration accelerates problem-solving, improves operational reliability, and leads to innovations that support safer, more efficient, and more sustainable flight operations. By uniting the practical insight of AMTs with the forward-looking vision of engineers, Texas can build an aerospace workforce that not only meets today’s needs but also drives the industry’s evolution for decades to come.

For example: The Aerospace Industries Association shows the aerospace and defense industry in Texas supported nearly 200,000 direct jobs in 2023, with total employment (including supply-chain jobs) of nearly 300,000. In parallel, a talent-pipeline study for North Texas found that while the region employed about 30,000 aerospace workers in 2016, it already identified that “new graduate supply does not meet employer demand for … avionics technicians, aircraft mechanics.” 

Companies must also adapt to the new reality that today’s engineering (and technical) workforce is interdisciplinary. The next aerospace workforce will blend traditional engineering with digital fluency — understanding materials, systems, software, and manufacturing simultaneously. For example, a recent cohort-training initiative at the University of Texas at Arlington (in collaboration with community colleges and industry) is training students in composite manufacturing, non-destructive testing, AI-enabled aerospace technologies, and virtual/augmented reality modules. 

Texas has always been a state that builds, innovates, and leads. By investing in its engineering and technical pipeline now, it can ensure that the next chapter of its aerospace story continues to soar — not stall — for decades to come.

Michael Campbell is president of ACD Consulting, a division of Coltala Aerospace, which supports aerospace and defense programs nationwide through advanced engineering and program management expertise.