Aerostructures Market Size, Share & Industry Analysis, By Components (Wings, Nose, Fuselage, Nacelle & Pylon, Empennage, and Others), By Material (Alloys, Composite, and Metals), By Platform (Fixed-Wing Aircraft (Commercial, Military, Business Jet, and General Aviation Aircraft) and Rotary-Wing Aircraft (Commercial Helicopters, Military Helicopters, and UAVs), and Regional Forecast, 2024-2032

The global aerostructures market size was valued at USD 116.09 billion in 2023 and is projected to grow from USD 123.25 billion in 2024 to USD 210.65 billion by 2032, exhibiting a CAGR of 6.93% during the forecast period. North America dominated the aerostructures market with a market share of 37.62% in 2023.

Aerostructures refer to aircraft airframe components that constitute the overall aircraft frame or body. The airframe includes single parts of an airplane capable of flight, such as the fuselage, nacelle, and nose. Rapid growth and expansion of key market players and increased air travel post-pandemic are expected to boost the global aerostructures market growth in the forecast period.

The airframe consists of components such as the nose, wings, nacelle & pylon, fuselage, and landing gear and doors. All these components join together to make a basic framework of an Aircraft. Different aircraft consist of various airframes, structures, and components. Increasing demand and adoption for chevron nozzle exhaust, a part of the nacelle, is expected to boost the market growth during the forecast period.  The COVID-19 pandemic dramatically impacted the annual orders and deliveries of the world's two leading commercial aircraft manufacturers. For instance, global deliveries in 2020 totaled 723 aircraft, 42% behind 2019 and 55.3% behind 2018, and marked the second consecutive year that deliveries declined. However, over a couple of years, the market has overgrown the decline and, due to increased passenger traffic, will be able to retreat to pre-pandemic demand.

Aerostructures Market Trends

Integration of 3D Printing to Act as a booster for the Market Growth

Original equipment manufacturers (OEMs) of aerostructure components have initiated the integration of emerging technologies for the efficient production of components, such as 3D printing. 3D printing primarily manufactures components, such as wings, panels, ducts, and others. 3D technology is used to reduce the number of components by printing two adjacent parts into one single component and producing lightweight parts. Other technologies, such as machine learning used in the production and integration of 3D printing help in the production, design, and manufacturing process of aerostructure and makes a whole component using a 3D model. For instance,

• In September 2022, GKN Aerospace, a global aerospace component manufacturer, unveiled the completion of its largest titanium structural aerostructure. The aerostructure manufacturing was aided with 3D printing and analytics to support effective and efficient utilization.  

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Aerostructures Market Growth Factors

Growing Demand for Modern Generation Engines with Chevron Nozzle Supports Market Growth

There is a surge in demand for a chevron nozzle, a triangular pattern exhaust nozzle extension that helps reduce noise and is equipped on modern jets. Chevron is used to reduce the levels of acoustics in the exhaust. This technology is adopted by the modern generation Boeing 747 & 787 and is found to reduce about 15 decibels of fan tones. The muzzle with a teeth-like structure reduces pressure variation, ultimately reducing jet noises. Growing demand for modern engines is a key factor driving the market growth. Moreover, airline operators around the world have placed bulk orders of aircraft and their engines. For instance,

• In January 2024, Akasa Air, one of India’s emerging airlines, placed a firm order of 300 CFM LEAP-1B engines for its recently ordered 150 Boeing 737 MAX aircraft. According to CFM International, the order was valued at USD 4.5 billion.

Increasing Use of Composite Material to Drive Market Growth

Composite materials are the first preference by OEMs to manufacture the airframe of airplanes owing to their relative properties such as durability, reliability, and toughness. Glass-reinforced plastics (GRP) and fiber-reinforced plastics (FRP) are composites mainly used to fabricate the skin and outer layers of the aircraft. GRP composite materials are produced using glass fibers and contain vinyl, epoxy, and polyester composites. FRP includes fibers and polymer resin. The fiber mainly provides strength to the material, and if related to polymer, it increases its inter-laminar shear strength. Thus, using composite material for aircraft structures reduces the overall weight of an aircraft.

• In February 2023, GKN Fokker, a Mexico-based manufacturer, delivered a thermoplastic composite aerostructure of 8m x 4m size. The aerostructure was made as a part of the multi-functional fuselage demonstrator (MFFD) project led by Airbus.

RESTRAINING FACTORS

High Cost of Maintenance and Repair to Limit Market Growth

Despite a rise in the demand for components, the high cost associated with procuring the components is predicted to restrain the market growth. The high cost associated with the maintenance and repair limits the market growth since aerostructure components aren’t refurbished after wear and tear. Therefore, any damage to the aerostructure directly leads to the complete change in the component and hence is cost taking.

For instance, in December 2022, the International Air Transport Association (IATA) unveiled the annual cost of ground damage to aircrafts would reach about USD 10 billion. Additionally, it is costly to acquire new components due to the complexity of the design and development and design. The integration and development of components across the aircraft and the maintenance of these components are expensive. Hence, these factors are anticipated to affect market growth negatively.

Aerostructures Market Segmentation Analysis

By Component Analysis

High Cost of Fuselage Led to the Dominance of Segment in this Market

Based on components, the market is categorized into wings, nose, fuselage, nacelle and Pylon, empennage, and others.

 The Fuselage segment accounted for the largest market share in 2022. The fuselage refers to the aircraft’s main body section that holds the cabin and cargo. The high cost associated with the aircraft’s body structure is a significant reason for the dominance of fuselage components in the market.

The wings segment is predicted to grow fastest during 2023-2030. The growth is due to rising demand for replacing conventional metal wings with composite aircraft wings. New-generation aircraft are lighter and demand lighter composite materials for their wings, too therefore, the segment is expected to experience the highest growth. 

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By Material Analysis

High Adoption Rate and Demand for Alloys Segment Dominates the Market

By material, the market is classified into alloys, composite, and metals. The alloys segment accounted for the largest market share in 2022, owing to the high demand for alloy material used in major aircraft components. There are several aerospace alloys, including Al and Mg, Ni, Co, and Ti based alloys. Al is the predominant metal in the system in aluminum-based alloys and alloying elements such as copper, zinc, manganese, silicon, and magnesium.

However, the composite material segment is expected to grow at the highest compound annual growth rate in the forecast period. The rapid growth in the segment is due to budding adoption for the development of the aircraft component. Composite materials built components offer high design strength, durability, flexibility, and low weight. These properties enable improved aircraft performance and reduce the overall weight. For example, for A350, 53% is composite content. For B787, 50% has composites content, and the Bombardier C-Series has 40% composites content.

By Platform Analysis

Owing to Broader Applications and Rising Fleet, Fixed Wing Segment Dominated the Market

Based on the platform, the market is divided into fixed-wing and rotary-wing aircraft. The fixed-wing aircraft is further divided into commercial, military, business jet, and general aviation aircraft. The rotary wing aircraft comprises commercial helicopters, military helicopters, and Unmanned Aerial Vehicles (UAVs).   

The fixed-wing segment dominated the market share in 2023, owing to wide availability and production prioritization to fixed-wing due to pertaining market demand. The growing air passenger traffic and expanding airline fleet were the major factors driving the segment’s growth in the base year. For instance,

• In November 2023, at the Dubai Air Show, airBaltic, the national carrier of Latvia, became the largest customer of Airbus A220 in Europe. The airline placed a confirmed order of an additional 30 A220-300s, taking the airline’s total firm order book to 80 aircraft.

The rotary-wing segment is predicted to record the highest CAGR during the forecast period. The rising procurement of military UAVs such as MALE and HALE for ISR applications supports the market expansion during the forecast period.

REGIONAL ANALYSIS

The global market regions are segmented as North America, Europe, Asia-Pacific, Middle East & Africa, and Latin America.

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North America market was valued at USD 43.67 billion in 2023 and is expected to dominate the market due to the presence of top OEMs in the region. For instance, in June 2023, U.S. government approved sale of 16 surveillance aircraft to Canada at cost of USD 6 billion. Similarly, rising demand across commercial airline also catalyze the market across North America. For instance, since January 2022, Air Canada has received more than 15 new aircrafts owing to expansion of their business activities.

Asia Pacific region is anticipated to grow at the highest CAGR during the forecast period due to the growing number of OEMs in the region. The region has been witnessing huge demand lately owing to a rise in UAV applications. The supportive government initiatives and the increasing defense budget further fuel the market's growth. The upsurge in the region's commercial and military aircraft development and procurement programs is anticipated to boost the market's growth.

• For instance, in August 2022, Japan unveiled the biggest order of attack drones after a recorded USD 40 Billion defense budget request.

Europe accounted for the second-highest market share in 2023. The region’s large share is owed to the growing demand for composite aerostructures. Additionally, key regional players are expected to boost the market in the forecast period.

The Middle East & Africa region will grow notably during the forecast period, owing to increasing initiatives by the government and global market players entering the market. A rise in military spending, growing demand, and emerging partnerships with global players and the emerging business jets market are expected to boost the market growth.

Latin America is expected to grow at a rising CAGR, owing to the budding market for aerostructure manufacturing. Additionally, frequent flyers are a major reason for the high number of aircraft deliveries in the reason leading to a growth in the market in the forecast period.

List of Key Companies in Aerostructures Market

Key Market Players Are Focused On Providing Advanced and Light Weight Aerostructures to Survive in the Market

The aerostructures market analysis is consolidated, with several global and regional players operating in this industry. Key market players have varied product portfolios, significantly focusing on producing lightweight aerostructures for OEMs. The top players in the industry are Airbus SAS, Bombardier Inc., and other listed companies in the ranking analysis. Leonardo SpA is expected to lead the market owing to its global presence.

Other prominent players involved in the market include SAAB AB, Triumph Group Inc., Cyient Ltd, and other market players highly involved in new product launches and frequent partnerships and acquisitions to sustain their market position.

List of Key Companies Profiled:

• AAR Corp (U.S.)


• Bombardier Inc (U.S.)


• SAAB AB (Sweden)


• Spirit Aerosystems Inc. (U.S.)


• Triumph Group Inc. (U.S.)


• Cyient Ltd (India)


• Elbit Systems Ltd (Israel)


• GKN Aerospace (U.K.)


• Leonardo SpA (Italy)


• The Boeing Company (U.S.)


• Airbus SAS (France)

KEY INDUSTRY DEVELOPMENTS:

• May 2023 – Massachusetts Institute of Technology, a prestigious institute, unveiled a technological advancement and inexpensive development to strengthen essential materials used today in aerospace and energy generation.


• April 2023 – Leonardo SpA, an Italian aerospace components and aircraft conglomerate, unveiled a partnership with Cisco Technology to develop joint technology projects. The partnership aims to develop joint products and solutions as a green transition to secure logistics and transportation solutions.


• February 2023 – Heart Aerospace, a Sweden-based electric aircraft developer, unveiled its selection as a long-term partner for air-New Zealand next-gen mission aircraft partnership. The partnership will bolster the replacement process of the airline’s Q300 domestic fleet.


• January 2023 – General Atomics Aeronautical Systems, Inc. (GA-ASI), a pioneer aerospace conglomerate, partnered with Bharat Forge, a forging company, to boost airframe manufacturing in India. The partnership includes manufacturing subassemblies, landing gear components, and remote-pilot aircraft assemblies.


• January 2024 – Airbus announced that it had signed a contract with Tata Advanced Systems Limited and Mahindra Aerospace Structures Private Limited to procure and manufacture commercial aircraft components and parts. According to the contract, TATA and Mahindra Aerospace Structures will manufacture parts, components, and assemblies for aircraft including Airbus' A320neo, A330neo, and A350.

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The market report provides detailed information on the market and focuses on leading companies, product types, and leading product applications. Besides this, the report offers insights into the market trends and competitive landscape, and highlights key industry developments. In addition to the above factors, it contains several factors that have contributed to the sizing of the global market in recent years.

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