Cost-Effectiveness of Structural Health Monitoring in Aviation: A Literature Review.

(1) Background: Structural Health Monitoring Systems (SHMSs) can reduce maintenance costs and aircraft downtime. However, their economic impact remains underexplored, particularly in cost-benefit terms. (2) Methods: This study conducted a targeted literature review on all the existing studies consisting of seventeen economic analyses of SHMS applications. Key features-such as SHMS type, structural material, vehicle type, integration stage, and cost elements-were classified to identify prevailing trends and gaps. (3) Results: The analysis revealed a predominance of piezoelectric-based SHMS applied to metallic fixed-wing aircraft, with limited attention to composite structures and e-VTOLs. Most studies focused on maintenance phase impacts, overlooking integration costs during manufacturing. Potential benefits like operational life extension, prognostic capabilities, and safety margin reduction were rarely explored, while critical drawbacks such as detection performance, reliability, and power consumption were underrepresented. Maintenance and fuel costs were the most frequently considered economic drivers; downtime costs were often neglected. (4) Conclusions: Although the majority of reviewed studies suggest a positive economic impact from SHMS implementation, significant gaps remain. Future research should address SHMS reliability, integration during early design stages, and applications to emerging aircraft like e-VTOLs to fully realize SHMS economic advantages.