Aero Engine Composite Material Market Size, Share & COVID-19 Impact Analysis, By Application (Commercial Aircraft, Military Aircraft, and General Aviation Aircraft), By Component (Fan Blades, Guide Vanes, Shrouds, Engine Casing, Engine Nacelle, and Other Cold End Parts), By Composite Type (Polymer Matrix Composites, Carbon Matrix Composites, and Metal Matrix Composites), By Fiber Type (Carbon Fibers, Ceramic Fibers, and Glass Fibers), and Regional Forecast, 2022-2029

The global aero engine composite material market size was valued at USD 2.53 billion in 2021 and is projected to grow from USD 2.87 billion in 2022 to USD 5.17 billion by 2029, exhibiting a CAGR of 8.76% during the forecast period. North America dominated the aero engine composite material market with a market share of 38.74% in 2021. Moreover, the aero engine composite material market size in the U.S. is projected to grow significantly, reaching an estimated value of USD 1782.6 million by 2029, driven by growing application of composites materials in technologically advanced engines to fuel the market size & growth.

The global COVID-19 pandemic has been unprecedented and staggering, with aero engine composite material experiencing lower-than-anticipated demand across all regions compared to pre-pandemic levels. Based on our analysis, the global market exhibited a decline of 7.2% in 2020 as compared to 2019.

Composite materials have been utilized in the aerospace industry for many decades, initially in non-safety critical applications and more recently as primary structures, including fuselage and wing structures on the latest aircraft from Boeing, Airbus, and Bombardier. An ever-growing aerospace market presents major opportunities to the U.K. composite sector to develop products and technologies for current and future platforms, with the capability of composite materials becoming more advanced and suited to applications across the entire aircraft environment.

Aircraft engine is one of the most contradictory and demanding environments for any material system. These aero engine designs are oriented toward the reduction of fuel consumption, higher thrust, and lighter weight for better fuel efficiency. Furthermore, the introduction of advanced aero engine composite material requires intensive and advanced development programs. Since 1980, average fuel burn on commercial aircraft has fallen by 27% for a wide body and 35% for a narrow body.

The rising production rate of commercial aircraft composites is driving the growth of the composites market for aircraft engines; aside from that, the use of ceramic matrix composites and metal matrix composites helps reduce weight for engines and allows them to run at much higher temperatures. However, the high capital investment and replacement cost of aero engine composite material may restrain the growth of the market.

COVID-19 IMPACT

Short Term Impact on Aircraft Deliveries Disrupted the Supply Chain of the Aero Engine Composite Market in 2020-2021

The outbreak of the COVID-19 pandemic and severe lockdown measures created a huge impact on the aviation industry, resulting in a short-term shutdown of flight and disruption in supply chain delays in aircraft and engine deliveries. Most airlines have canceled their aircraft orders due to a deficiency in passenger demand, which will also affect the aircraft engine market. Moreover, due to the impact of COVID-19, the supply chains of aero engine composite material were also disrupted due to the lockdowns, leading to a slowdown in the production of backlog orders. For instance,

• Airbus delivered a total of 566 jets in 2020 as compared to 863 deliveries in 2019. Similarly, the Boeing Company delivered a total of 157 aircraft in 2020 as compared to 380 deliveries in 2019. These aircraft deliveries have negatively impacted the demand for aircraft engines and, subsequently, the demand for composite components used in these new aircraft.

LATEST TRENDS

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High Adoption of Ceramic Matrix Composite in Hot Section of Engine to Boost the Market Growth

Ceramics and ceramic-metal mixtures are used in the hot section of the engine that is in the combustion chambers due to their high heat resistance. They have very high melting points and do not require cooling systems, so they are used for manufacturing lighter, less complicated engine parts. Ceramics is the most vital part of the aero engine composite material business as a number of scientific and manufacturing innovations use this material to create Ceramic Matrix Composites (CMC), which are highly advanced in nature and exhibit high hardness and strength without losing their superior heat treatment properties of ceramic and glass. Composed of silicon carbide (SiC), ceramic fibers, and ceramic resin, CMCs are manufactured using a sophisticated process and further enhanced with proprietary coatings. Key players involved in the market are taking initiatives and spending more on material development techniques to boost their sales in the market. For instance,

• At General Aviation, CMC development is the culmination of USD 1.5 billion in investment and decades of research, which led to crucial advances in GE engines used in military and civilian aircraft.

DRIVING FACTORS

Growing Application of Composites Materials in Technologically Advanced Engines to Fuel the Market Growth

Technological advances in a variety of composite blends are a key driving factor in the aero engine composite material market growth. Manufacturers of aero engine composite materials are significantly focused on implementing advanced aero engine composite material manufacturing techniques that increase engine fuel efficiency and reduce CO2 emissions. Aircraft engines with high fuel efficiency reduce carbon emissions and also reduce operational costs. Additionally, many government organizations have implemented new emission regulations, due to which the demand for fuel-efficient engines has aided the market. Moreover, key players such as GE Aviation, Solvay SA, Meggitt PLC, and others are focused on enhancing their portfolios and manufacturing fuel-efficient engines using comprehensive technologies to withstand the market competition. For instance,

• In December 2019, Solvay and SGL Carbon signed an agreement to bring to market the first composite materials based on large-tow intermediate modulus (IM) carbon fiber. These materials clarify the need to reduce costs and CO2 emissions. Moreover, it is also focused on improving the production process and fuel efficiency of next-generation commercial aircraft. This agreement considers both thermoset and thermoplastic composite technologies.

RESTRAINING FACTORS

High Cost Associated with Composite Materials to Hinder the Market Growth

Though composite materials are widely used in the aerospace industry, high manufacturing cost for their production has hampered the growth of the market. Moreover, difficulty in repairing composites compared to metallic structures is also restraining the market growth. The higher cost associated with aero engine composite materials is due to the price of the fiber and the complex process required to manufacture the final material. In addition, it is difficult to determine when the internal structure of composite aircraft components has been damaged. This makes inspection difficult and costly. The machinery and tools required to manufacture thermoplastic and other composites are cost-intensive and result in high product costs. Hence, it is not commercially viable to adopt composite materials on a large scale. Moreover, structural composite damagers' claim cost is higher than alloy-constructed counterparts.

For instance, recently, an incident involving a baggage cart collision with a Boeing B777 with an alloy nacelle had claims costs of USD 2.5 million. These costs are much higher for the repair of advanced composite components.

SEGMENTATION

By Application Analysis

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Commercial Aircraft Segment Holds the Largest Position due to Rise in Demand for Modern Generation Engine

Based on application, the market is segmented into commercial aircraft, military aircraft, and general aviation aircraft.

The commercial aircraft segment is estimated to be the largest segment with a significant market share in 2021. The rising demand for commercial aircraft and modern generation aircraft engines due to growing air passenger traffic is anticipated to fuel the market growth. Moreover, airline operators accept low-cost subsidiary airlines' concepts to increase their revenue. Thus, higher segment growth is projected during the forecast period.

The military aircraft segment is one of the emerging segments in the market owing to increased procurement of military aircraft due to high defense expenditure countries and increased popularity of high bypass engines in military aircraft, which is expected to propel the growth of the segment. Moreover, increased demand for aircraft for surveillance applications in the military boosts the segment growth during the forecast period.

By Component Analysis

Engine Casing Segment to Dominate Market due to High Demand for Lightweight Engine Cowls

Based on component, the market is segmented into fan blades, guide vanes, shrouds, engine casing, engine nacelle, and other cold end parts.

The engine casing segment is expected to dominate the market. The growing aerospace industry with increasing demand for lightweight aircraft is expected to increase the development of lightweight engine casings and cowls made up of composite materials such as carbon fiber. Moreover, the modern generation engine casing is now designed to reduce the noise produced by the engine to a greater extent. Thus, higher growth numbers are expected during the forecast period.

The fan blades segment is one of the emerging segments during the forecast period owing to the growing demand for fan blades to power both narrow-body and wide-body engines. These engines are light in weight and provide a high thrust-to-weight ratio. For instance, the GE90 fan blades are made of carbon-fiber composite and it's the world’s largest and most powerful jet engine.

The engine nacelle segment is anticipated to reach higher growth numbers. The growth is attributed to increased demand for aircraft with advanced nacelle systems and solutions. The growing demand for composite nacelles are designed for lower weight to provide better engine fuel economy to boost the segment growth during the forecast period. Moreover, the increased R&D for a sustainable aviation future will boost the segment growth during the forecast period.

By Composite Type Analysis

Due to High-temperature Absorbing Capabilities, Carbon Matrix Composite Segment to Witness High Growth during the Projection Period

Based on composite type, the market is segmented into polymer matrix composites, carbon matrix composites, and metal matrix composites.

The carbon matrix composites segment is estimated to witness higher growth rates during the projection period 2022-2029. Increasing demand for carbon matrix composites for modern engine casing applications in commercial and military aircraft boosts segment growth. Moreover, carbon matrix composites are a special kind of aero-engine composite material that consists of carbon fibers embedded in a carbonaceous matrix. Carbon is an excellent high-temperature material. Carbon fiber has been used everywhere in aircraft; the Boeing 787 Dreamliner passenger plane is composed of 50% composite material by weight, with most of the composite material being carbon fiber laminate or carbon fiber sandwich.

The polymer matrix composites segment held a significant market share in 2021 and was estimated to show remarkable growth during the forecast period. The advanced polymer matrix composites have high shock absorbance capacity and innovative structure design, hence providing more safety to the engine and aircraft. Thus higher growth numbers are anticipated during the forecast period.

The growing use of metal matrix composite due to high strength and stiffness and low density compared with nickel- and steel-base materials boosts the segment growth. Titanium metal-matrix composites (MMC) are widely used materials for engine applications owing to their excellent high-temperature longitudinal strength. Thus, higher growth numbers are anticipated during the forecast period.

By Fiber Type Analysis

Ceramic Fiber Segment dominates the segment Owing to its Lighter Weight Properties 

Based on fiber type, the market is segmented into carbon fibers, ceramic fibers, and glass fibers.

The ceramic fibers segment is estimated to witness significant CAGR during the forecast period owing to the high adoption of ceramics into jet engines and turbines that increase engine efficiency due to their lighter weight and better thermal capabilities. A jet engine employing ceramic composites has manifested 15% more fuel savings when compared to simple nickel-based alloys. Moreover, ceramic fibers can be used at temperatures up to 2,200°F. Thus, higher growth numbers are anticipated during the forecast period.

The carbon fibers segment is estimated to be the largest segment in the market, owing to the growing demand for lightweight fan blades made up of carbon fiber to boost the segment growth. Moreover, these modern-generation carbon fiber fan blades are now advanced, lightweight, and made of sustainable material. Thus, higher growth numbers are expected during the forecast period. For Instance,

• Rolls-Royce stated that its fan blades are made up of hundreds of layers of carbon fiber materials that are pre-filled with resins. After applying heat and pressure, each blade is finished with a thin titanium leading edge that reportedly offers protection from erosion, debris, and bird strikes.

REGIONAL INSIGHTS

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The market is segmented into North America, Asia Pacific, Europe, and the Rest of the World.

North America dominated the market in 2021. North America market size stood at USD 0.98 billion in 2021. The growth is attributed to the presence of a large number of players and the presence of aircraft manufacturers and engine component manufacturers. In addition, the U.S. government is investing in the quality and effectiveness of transport aircraft and their engines, which is expected to fuel the growth of the market. In addition, increasing defense investment in the procurement of combat aircraft, military helicopters, single-engine aircraft, and rescue helicopters is expected to drive the market in North America.

Europe, the hub of engine manufacturers, has higher growth numbers anticipated during the forecast period. Key players involved in the market are setting up plants to manufacture composite engine components. For instance, in 2020, Rolls-Royce opened a new facility in Bristol, U.K. to develop carbon fiber composite fan blades and fan cases for use on jet engines.

The market in Asia Pacific is expected to grow at the highest CAGR during the forecast period. Air passenger traffic in Asia Pacific is encouraging the need for new aircraft and modern-generation engines. Moreover, improving the economy and rising defense expenditure of emerging countries such as India and China boost the market growth in the region. In addition to the rising military budget, a surge in demand for new aircraft from China and India is expected to fuel the growth of the aero engine composite material market.

In addition, the market growth in the rest of the world will see higher growth figures due to the development of the aerospace sector in the Middle East and Africa due to the large number of commercial airlines registered in the region. The growing investments by Middle East & African airlines for aircraft and engine procurement will fuel the market growth during the forecast period.

KEY INDUSTRY PLAYERS

Strong Product Portfolio of GE Aviation to Lead the Market

The market is highly consolidated as a few companies control the large market share. GE Aviation, a subsidiary of General Electric Company, is a leading supplier of turboprop and jet engines. With outstanding product technology and a diversified product portfolio, the company aims to dominate the world market. Other major players in the market are Rolls Royce Holdings Plc., Safran SA, Meggitt Plc, and others. The introduction and upgrading of advanced aero engine composite material processing technologies to offer their customers an improved product portfolio is the key strategy of the major players in the market.

LIST OF KEY COMPANIES PROFILED:

• Rolls Royce Holdings Plc (U.K.)


• GE Aviation (U.S.)


• Hexcel Corporation (U.S.)


• Meggitt Plc (U.K.)


• Albany International (U.S.)


• Nexcelle LLC (U.S.)


• Solvay (Belgium)


• DuPont de Nemours, Inc. (U.S.)


• Safran SA (France)


• FACC AG (Austria)

KEY INDUSTRY DEVELOPMENTS:

• July 2022 – Hexcel Corporation joined hands with Spirit AeroSystems at its Aerospace Innovation Centre (AIC) to develop more sustainable aircraft manufacturing technologies for future aircraft production.


• March 2021 – GE’s CMC turbine shrouds surpassed 10 million hours in flight in the hottest section of the CFM* LEAP engine in 2021, and more than 100,000 of those turbine shrouds have been produced at scale at its state-of-the-art production facility in Asheville, North Carolina. The world’s largest commercial engine, the GE9X, has five different CMC parts in its hot section.


• July 2022 – Hexcel celebrated the successful maiden flight of Airbus 321XLR. Hexcel is a major supplier of advanced composite materials for the A321XLR airframe and the CFM International LEAP-1A engine that powers today's aircraft. These innovative lightweight composite materials provide weight savings and performance enhancements that reduce fuel consumption and emissions as well as long-term maintenance costs.


• February 2022 – Albany Engineered Composites (AEC) was selected by Sikorsky Aircraft to produce the complete CH-53K Aft Transition assembly in a competitively bid 10-year long-term agreement. This long term agreement is already underway to support the schedule, and the contract is expected to be finalized in the first quarter of 2022, with the first deliveries in 2023.


• July 2021 – Pratt & Whitney, a division of Raytheon Technologies Corporation, announced the launching of a Ceramic Matrix Composites (CMCs) development and engineering facility, which is an integrated development, engineering, and low-cost production facility dedicated to CMCs for aerospace applications.

REPORT COVERAGE

An Infographic Representation of Aero Engine Composite Material Market

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The research report offers a detailed analysis of the market and focuses on key aspects such as leading companies, product types, and leading applications of the product. Additionally, the report provides insights into the market trends and highlights key industry developments. In addition to the factors mentioned above, the report encompasses several factors that have contributed to the growth of the market in recent years.

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