Aerostructures Market Size, Share & Growth

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The Global Aerostructures Market Size was valued at USD 61.0 billion in 2023 and is estimated to reach USD 84.0 billion by 2028, growing at a CAGR of 6.6% during the forecast period. The Aerostructures Industry is driven by factors such as technological advancements in aerostructures, expansion of MRO services and decline in cost of composite materials.

Aerostructures Market Forecast to 2028

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Aerostructures Market Dynamics

Drivers: Preference for efficient and sustainable aerostructures

In the aerostructures business, efficiency and sustainability are two significant forces influencing design, production, operation, and maintenance. Efficient aerostructures lower the weight of the aircraft and reduce fuel consumption, thereby enhancing the performance of the aircraft. These sturdy and lightweight structures, which can endure the stresses of flight using less fuel, are made with cutting-edge materials and technologies. Aerostructures with improved aerodynamics lower drag, further reducing emissions. Due to increased environmental concerns related to air travel among airlines and passengers, sustainability is becoming pivotal to the aerostructures business. In addition to lowering carbon emissions, sustainable aerostructures are meeting the need for eco-friendly goods and services. Consequently, eco-friendly products, production techniques, and propulsion systems are being created, such as composites made of recycled materials or biofuels that emit less carbon. Airlines are also enhancing their environmental profile by investing in sustainable aerostructures.

The production and maintenance of aerostructures is also influenced by efficiency and sustainability. Automation and digitalization assist in streamlining industrial processes, cutting waste, and improving efficiency. Robotics and machine learning are being used to produce aerostructures with higher quality, fewer mistakes, and lower costs. Digital tools are used to track the performance of aerostructures, providing real-time information on fuel consumption, wear and tear, and other metrics that can help airlines run more efficiently and economically.

Restraints: Obstacles associated with recycling composite materials

Compared with single material-made wastes, composite wastes are more challenging to recycle, mechanically or chemically, due to inconsistencies in chemical compositions and material properties. Considering their innate properties of lightweight, durability, and longevity, composite materials contribute to the development of sustainable solutions for assemblies and structures across industries. However, stricter environmental policy and legislation, increased restrictions and costs for landfill disposal, and the transition to a circular economy are some factors to be considered for creating recycling solutions for composites. Increased use of lifecycle assessments as part of the materials selection process across many sectors is also scrutinizing composites’ end-of-life waste management. Furthermore, there are nearly 11,000 tonnes of E-glass fiber waste from earlier stages of the supply chain. It is also estimated that around 1,600 tonnes of carbon fiber/carbon-fiber-reinforced plastic (CFRP) production waste may be generated annually. While there is relatively little carbon fiber end-of-life waste at present, significant volumes are expected to join the waste stream soon. Therefore, due to the recyclability issues of composite materials, the manufacturing of aerostructures is restrained.

Opportunities: High demand for UAVs

The unmanned aerial vehicle (UAV) demand has opened up enormous possibilities for the aerostructures market. Drones, often known as UAVs, have a variety of uses in the consumer, business, and military sectors. Due to their numerous uses in surveillance, agriculture, transportation, and delivery services, UAVs are anticipated to expand rapidly over the next several years. In order to enhance their flying performance and increase their range and endurance, innovative aerostructures made of lightweight composite materials are being developed in response to the growing demand for UAVs.

Players in the aerostructures market are investing in the development of new technologies and materials to assist the production of UAVs as consumer demand for them rises. This creates more chances for producers of aerostructures to increase their capabilities and domain knowledge in aerodynamics, materials science, and innovative production techniques. Businesses are also looking into novel business models to offer a variety of services, including design, prototyping, and testing, to aid in the development of UAVs.

Furthermore, the growth of autonomous UAVs gives aerostructure businesses a chance to provide fresh services such as maintenance, repair, and overhaul (MRO). Companies will need to provide new MRO services to support their operations as the use of autonomous UAVs increases, which will call for knowledge of modern aerostructures. The growing demand for UAVs presents tremendous potential for the aerostructures market to establish new business models and services and extend its capabilities.

Challenges: Supply chain constraints and high shipping costs

One of the challenges that aerostructure manufacturers need to overcome is the high cost of transportation and hurdles in the supply chain. High transportation costs are driving supply chain strategies. The changes in transport costs have an impact not just on transportation budgets but also on the broader supply chain and financial performance.

Reasons for high-cost transportation:

• High freight rates
• Outdated warehouse network
• Out-of-area shipping
• Poor compliance with prescribed routings
• Split shipments

A conjunction of factors and economic developments lies behind the rising transportation costs. Freight movement in most modes largely depends on increasingly expensive and finite fossil fuels, primarily diesel fuel. According to the US Energy Information Administration, the price of crude oil is the dominant factor influencing changes in diesel prices. Another equally influential factor in transportation costs is the demand-supply imbalance of freight transport services, a repercussion of trade growth that has outpaced the availability of transport services to such an extent that it has led to severe issues of congestion and capacity constraint in the US. According to a report presented in September 2021 at the Council of Supply Chain Management Professionals (CSCMP) annual conference, overall logistics costs in the US fell by 4% to USD 1.56 trillion. The drop was primarily driven by a 15% decrease in inventory carrying costs. The report stated that transportation costs increased by 0.8%, driven by a 24.3% increase in the parcel and last-mile segment from e-commerce and home delivery growth. Also, airfreight costs increased by 9%, the motor was down 0.6%, the ocean was down 28.6%, and rail was down 11%. Costs continued to fluctuate throughout 2021 and are currently trending up. Thus, the increase in transportation costs and hurdles in the supply chain will have an adverse effect on the aerostructures market.

Aerostructures Market Ecosystem

Based on end user, the aftermarket segment of the market is projected to grow at the second highest CAGR from 2023 to 2028.

Based on end user, the aerostructures market has been segmented into OEM and aftermarket. The increasing maintenance, repair and replacement activities is driving the aftermarket segment. Aging od aircraft fleet, Increasing utilization of aircraft, increasing upgrades and retrofits is also influencing the growth of this segment.

Based on material, the alloys & superalloys segment of the market is projected to grow at the second highest CAGR from 2023 to 2028.

Based on material, the aerostructures market has been segmented into composites, alloys & superalloys, and metals. The need to withstand high temperatures, high resistance to fatigue and high strength is driving the growth of this segment. The increased research on developing new alloys & superalloys with improved properties such as reduced weight, enhanced resistance and increased strength also is influencing the growth of this segment.

Based on aircraft type, the UAVs segment of the market is projected to grow at the second highest CAGR from 2023 to 2028.

Based on aircraft type, the aerostructures market has been segmented into commercial aviation, military aviation, business & general aviation, unmanned aerial vehicles (UAVs) and advanced air mobility (AAM). The demand for UAVs is due to its increasing applications of UAVs for military and commercial use. The demand for lightweight design and customized designs are also driving the UAVs segment in the aerostructures market.

North America is expected to account for the highest CAGR in the forecasted period.

North America is estimated to account for the highest CAGR in the forecasted period. The increasing demand for commercial aircrafts is majorly driving this growth of the market. US and Canada are the countries studied under this region. The presence of leading aerostructure manufacturers and increasing R & D investments is influencing growth in this segment

Aerostructures Market by Region

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Key Market Players

Players such as Airbus SE (Netherlands), FACC AG (Austria), Elbit System Ltd. (Israel), ST Engineering (Singapore) and Ruag Holding AG (Switzerland). The report covers various industry trends and new technological innovations in the Aerostructures Companies for the period 2020-2028.

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Scope of the Report

Aerostructures Market Highlights

The study categorizes aerostructures based on component, material, aircraft type, end user, and region.

Recent Developments

• In March 2023, Spirit AeroSystems Inc. and Joramco have signed an agreement to be a spirit-authorized maintenance, repair, and overhaul (MRO) center. Under this agreement, they will first provide nacelle services to selective players and their products.
• In December 2022, Airbus SE announced the extension of its contract with Axiscades Technologies Ltd. to provide engineering services for the design and development of Airbus aircraft programs. The contract will provide engineering services and product development for fuselage and wings at different locations.
• In September 2022, Spirit AeroSystems Inc. received a contract from The Boeing Company to provide horizontal stabilizers for its KC-135R Stratotankers used by US Airforce.
• In October 2022, Air Force Research Laboratory has awarded a contract to Collins Aerospace to design and build an advanced impact resistant F-16 ventral fin using thermoplastic welding technology. The contract is for three years, under which the company will make component design, application of welding process, and fabrication of F-16 fin.
• In January 2022, GKN plc signed an agreement with Gulfstream for major workshare, including G800 empennage, G800 floorboards, G800 fuselage panels, G400 rudder, and G400 machined wing skins.

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