Aerostructures Market

Market Overview

The global aerostructures market size was valued at USD 66.5 billion in 2023 and is projected to reach  USD 122.3 billion by 2032, registering a CAGR of 7.0% during the forecast period (2024-2032). The global expansion of commercial aircraft deployment is a crucial driver of aerostructures market growth.

Aerostructures are the components or sections of an aircraft's airframe that contribute to structural integrity, aerodynamic performance, and overall function. These components are often built with modern materials and precision engineering techniques to meet stringent safety, reliability, and performance requirements. Aerostructures range in complexity and scale from small structural elements like ribs and stringers to massive assemblies like fuselage sections, wings, empennage (tail assembly), and landing gear.

Stringent environmental regulations, growing demand to minimize and optimize operational costs, and rising awareness and concern about environmental issues are all pushing the aerostructures industry. The market is expanding, but high start-up costs, technology acceptance, and integration issues impede it. Furthermore, the growing trend towards automation and business intelligence solutions, combined with technical improvements, creates significant potential prospects for aerostructures market participants.

Top 3 Key Highlights

• Fuselage dominates the market by component.
• Alloys account for the largest share of the market by material.
• Fixed-wing aircraft influenced the market by platform.

Market Dynamics

Market Drivers

Rising Air Passenger Traffic

The constant increase in global air passenger traffic is a significant driver of the aerostructures market. As more individuals choose air travel for business and pleasure, airlines want to grow their fleets or replace older planes with newer, more fuel-efficient models. This increases demand for aerostructures, such as fuselage sections, wings, and empennage, which support aircraft manufacture. The International Air Transport Association (IATA) predicts that worldwide passenger traffic will rise to 9.4 billion in 2024, up from 8.6 billion in 2023. This is more than double the prediction for 2024, with almost 20 billion in 2042 and nearly 25 billion in 2052. Rising disposable incomes, urbanization, and intercity connectivity contribute to this expansion.

According to Airbus's 2023 Global Market Forecast (GMF), passenger traffic demand is predicted to increase by 3.6% annually between 2019 and 2042. This represents increased energy expenditures and the possible effects of anticipated price elasticity of demand. The GMF also anticipates that 40,850 new passenger and freighter aircraft will be delivered over the next 20 years, including 32,630 single aisle and 8,220 widebody. As airlines expand their fleets to accommodate rising passenger traffic, there is a strong demand for new aircraft. Aerostructure manufacturers play an essential role in addressing this need by providing components like fuselage sections, wings, and empennage. Additionally, the necessity to upgrade older aircraft with contemporary aerostructures to improve fuel efficiency and passenger comfort drives market demand. Thus, rising air passenger traffic needs close collaboration across the aerospace supply chain. Aerostructures manufacturers collaborate closely with OEMs, suppliers, and regulatory authorities to ensure the timely delivery of high-quality components that meet safety and regulatory requirements. This collaborative approach is vital for the aviation industry's long-term prosperity.

Market Restraints

High Development and Manufacturing Costs

Developing and constructing aerostructures, particularly those made from sophisticated materials such as carbon fiber composites, is expensive. For example, manufacturing composite wing structures requires specialized facilities, equipment, and expert labor. These investments significantly increase the overall cost of airplane production. The cost of creating a new commercial aircraft program can range from billions of dollars to USD 20-30 billion or more. The price is considerable because aircraft are sophisticated machines, and most money is spent on research and development. For example, Airbus spent USD 25-30 billion on the A380 program between 2016 and 2020, which included research, development, and manufacturing. 

Additionally, small and medium-sized firms (SMEs) in the aerospace supply chain may need help to obtain the capital and resources required for technological development and process improvement. The substantial initial expenses associated with developing or upgrading manufacturing facilities may discourage SMEs from joining the market or expanding their capabilities. Moreover, high development and manufacturing costs present issues for aerostructure manufacturers and tiny suppliers with limited financial resources. They may need help to make the initial investments in infrastructure, technology, and staff training required to manufacture aerostructures to OEM requirements. 

Market Opportunity

Technological Advancement and Digitalization

Rapid technological breakthroughs, including additive manufacturing, enhanced robotics, and digital twin simulations, are transforming the aerospace production scene. Aerostructure makers can use these technologies to increase productivity, streamline design and production processes, and provide customized solutions that meet the specific needs of aircraft OEMs and operators.

Airbus and Autodesk cooperated to produce the "bionic partition," the world's most significant 3D-printed cabin component. The barrier between the passenger compartment and the galley in the Airbus A320 is composed of Scalmalloy, an aluminum-magnesium-scandium alloy that is 45% lighter than current designs. The partition is intended to resemble real animals' organic cellular structure and bone development. The bionic partition uses unique algorithms to build a design that mimics cellular structure and bone formation, which is subsequently produced using additive manufacturing. Furthermore, additive manufacturing allows aerostructure makers to improve production processes, shorten lead times, and maximize material utilization. By combining several components into a single, integrated structure, additive manufacturing decreases assembly complexity and removes the need for traditional manufacturing tools, resulting in cost savings and increased production efficiency. Additive manufacturing enables the fabrication of highly customized, complicated geometries that are difficult or impossible to produce using traditional manufacturing methods. This feature allows for lightweight, aerodynamic efficiency, and structural integrity design optimization, resulting in higher aircraft performance and fuel efficiency.

Regional Analysis

The global aerostructures market analysis is conducted in North America, Europe, Asia-Pacific, the Middle East and Africa, and Latin America.

North America is the most significant global aerostructures market shareholder and is estimated to grow at a CAGR of 6.7% over the forecast period. North America, notably the United States, boasts a long-standing and robust aircraft sector. The presence of major aerospace companies such as Boeing and Lockheed Martin adds to the region's dominance in aerostructure manufacturing. Furthermore, the area is home to some of the world's largest aircraft manufacturers, such as Boeing and Airbus (which has a strong presence in North America). These companies fuel the need for innovative aerostructures, and their manufacturing facilities are centered in the region. In addition, the area is home to various aerospace-focused research and innovation facilities. Research and development (R&D) investments promote aerostructure innovation, providing North American enterprises with a competitive advantage in delivering cutting-edge solutions. 

Furthermore, the United States has the world's most significant defense budget, which places a high priority on researching and constructing military aircraft. The demand for advanced aerostructures in the defense sector reinforces North America's position in the worldwide market. Furthermore, North American aerospace businesses frequently form strategic alliances and collaborations with domestic and international entities. These agreements strengthen the region's aerostructure development, manufacturing, and export capabilities. Furthermore, North American aerospace businesses have built a global network of suppliers, ensuring a dependable and efficient supply chain. This network allows for the timely and cost-effective production of aerostructures, leading to market dominance.

Asia-Pacific is anticipated to exhibit a CAGR of 7.3% over the forecast period. The Asia Pacific region is expected to expand at the fastest CAGR over the projection period due to an increasing number of OEMs. The area has recently experienced high demand due to increased UAV applications. Government initiatives and increased defense budgets drive industry expansion. The region's growing commercial and military aircraft development and purchase programs will expand the market. By 2025, China is expected to have the world's largest aviation market in terms of air traffic. India is expected to become the world's third-largest aviation market, with Indonesia and Thailand joining the top ten.

Additionally, lower production costs further assist the aviation manufacturing infrastructure, encouraging major aircraft OEMs to build regional manufacturing hubs. For example, Airbus has established industrial agreements with around 600 enterprises in 15 regional countries to ensure the supply of parts for Airbus aircraft. KAL Aerospace and Korea Aerospace Industries (KAI) are significant suppliers to Airbus, producing aerostructures such as the A350 XWB fuselage, wing, cargo door, and landing gear, as well as the Sharklet wingtip device for the A320 and A330neo aircraft.

Furthermore, in April 2023, Airbus plans to increase production of its best-selling A320 single-aisle plane and boost sales in China. Airbus intended to create a second production line at its factory in China, and Beijing approved the previous order for 160 aircraft.  Europe had the second-highest market share in 2023. The region's significant contribution is attributed to increased demand for composite aerostructures. Furthermore, prominent regional players are projected to increase the market over the forecast period. The Mubea Group, a German family-owned company, is slated to acquire RUAG Aerostructures Germany & Hungary. This new ownership provides an ideal platform for expanding Aerostructures Germany and Hungary's capabilities. It intends to strengthen the unit's technological leadership, dependability, and flexibility, establishing it as the only provider of the Airbus A320 series. 

The Middle East and Africa area is expected to experience significant growth over the forecast period, driven by government efforts and global market participants. The market for business jets is predicted to grow due to increased military spending, rising demand, and new alliances with international players. Latin America, on the other hand, is predicted to develop at a higher CAGR due to the emerging market for aerostructure manufacture. Frequent flyers account for many aircraft deliveries, contributing to market growth throughout the projection period. 

Segmental Analysis

The global aerostructures market is segmented based on components, materials, and platforms.

The market is further segmented by components into wings, nose, fuselage, nacelle and pylon, and empennage.

The fuselage segment led the market in 2023, accounting for around 35%. The fuselage is the primary body structure of an airplane, containing the flight crew, passengers, cargo, and essential equipment. It provides structural support and contains critical components such as the cabin, cargo compartments, fuel tanks, and landing gear. Aerostructure manufacturers develop and produce fuselage sections from various materials, including aluminum, titanium, and composites, to achieve the necessary balance of strength, durability, and weight. As such, it accounts for a sizable component of the entire aerostructure, making a considerable contribution to the market.

Furthermore, the ongoing increase in air travel demand and the requirement for new aircraft contribute to fuselage manufacturing's leading position in the aerostructures market. Fuselage production becomes a priority as airlines and manufacturers attempt to fulfill increased demand. Furthermore, the fuselage incorporates various sophisticated technologies, including avionics, connection systems, and structural improvements. Manufacturers concentrate on integrating these technologies into the fuselage design, which adds value to the whole aircraft and drives demand for sophisticated aerostructures. Wings are key airplane components that generate lift and control flight. They comprise aerodynamic surfaces, such as airfoils, that create lift as the aircraft passes through the air. Wings also store fuel tanks, control surfaces (such as ailerons and flaps), and high-lift devices, which improve performance during takeoff, landing, and maneuvering. Aerostructures manufacturers create and build wing structures from modern materials, including composites and aluminum alloys, to maximize strength-to-weight ratios and aerodynamic performance.

The market can be bifurcated by material into alloys, composites, and metals.

The alloys category dominated the market due to the rising demand for alloy materials in aviation components. Alloys are metallic materials of two or more elements, commonly containing metals like aluminum, titanium, and steel. Aircraft components built of alloys have high strength-to-weight ratios, corrosion resistance, and longevity, making them appropriate for a wide range of aerostructure manufacturing applications. Alloys are widely utilized in wing structures, fuselage sections, and engine components because of their excellent tensile strength and fatigue resistance. Advanced aluminum alloys, such as the 7000- and 2000-series, are commonly employed in aircraft applications due to their lightweight characteristics and machinability. 

The composite material segment is predicted to have the most significant compound annual growth rate during the forecast period. The segment's high rise can be attributed to growing utilization in airplane component development. Composite materials provide components with excellent strength, durability, flexibility, and low weight. These qualities enhance aircraft performance and reduce overall weight. For example, the A350 has 53% composite material. B787 has 50% composites content, while Bombardier C-Series has 40% composites.

Based on the platform, the market is fragmented into Fixed-Wing Aircraft (Commercial, Military, Business Jet, and General Aviation Aircraft) and rotary-wing Aircraft (Commercial Helicopters, Military Helicopters, UAVs).

The fixed-wing aircraft segment is further classified as business jet, commercial, general aviation, and military. The rotary-wing aircraft segment is divided into three categories: commercial helicopters, military helicopters, and uncrewed aerial vehicles. Fixed-wing aircraft dominated the market in 2023, accounting for around 70%. Fixed-wing aircraft are the most common transportation method for passengers and cargo. Fixed-wing aircraft are vital for long-haul and transcontinental travel because of their ability to transport large numbers of people and significant cargo payloads, contributing to their dominance in aerostructure demand. 

Fixed-wing aircraft are also commonly utilized in military applications, such as fighter jets, bombers, reconnaissance planes, and transport aircraft. The military aviation sector generates significant demand for advanced aerostructures, which supports fixed-wing platforms' leading position in the market. Fixed-wing aircraft also provide global connection, allowing for efficient and fast transit between distant areas. As globalization continues, the demand for fixed-wing aircraft and aerostructures for international travel and trade remains high. Rotary-wing aircraft, or helicopters, use revolving blades or rotors to generate lift and drive, allowing for vertical takeoff and landing (VTOL) capabilities. Helicopters are adaptable aircraft used for various purposes, including military missions, search and rescue operations, medical evacuation, law enforcement, and civilian transportation.  Aerostructures for rotary-wing aircraft include central rotor systems, tail rotor assemblies, fuselage structures, and landing gear. These components are intended to endure the dynamic loads and vibrations that occur during helicopter operations while maintaining stability, maneuverability, and safety. Aerostructures producers use specialized engineering techniques and materials to improve the performance and dependability of rotary-wing aircraft components while adhering to demanding regulatory requirements and industry standards.

Recent Developments

• March 2024- GKN Aerospace will explore and build partnerships with companies working on various power and propulsion systems and disruptive technologies, which are expected to play a vital role in future air combat capabilities.
• March 2024- Boeing [NYSE: BA] and Ethiopian Airlines announced an agreement for the East African airline to purchase eight 777-9 passenger planes, with the option for up to 12 more jets.
• February 2024- Elbit Systems, a global defense technology pioneer, introduced the latest addition to its market-leading Hermes family. This Next Generation Unmanned Aerial System (UAS) provides exceptional endurance, versatility, and cost-effective performance in land, air, and marine operations.