Unidirectional Tape Market

Market Overview

The global unidirectional tape market size was valued at USD 317.30 million in 2022. It is estimated to reach USD 764.86 million by 2031, growing at a CAGR of 10.27% during the forecast period (2023–2031). The major driver for the global unidirectional tape market is its increasing demand from the aerospace industry owing to numerous advantages of unidirectional tape, such as its high strength, stiffness, and abrasion resistance. In addition, UD tape is formed of reinforcement material like carbon fiber, a lightweight material, and there is an increase in demand for such materials from industries like automotive and energy, particularly wind energy, thus boosting market growth.

Unidirectional tapes consist of fibers impregnated with a resin matrix; all fibers travel in the same direction. Unidirectional Tape (UD) tapes are composite materials comprised of glass fibers, carbon fibers, and other types of fibers. UD tapes have high tensile strength, tensile durability, rigidity, and impact resistance. UD tapes are high-tech composites that offer a diverse array of fiber or resin composites. These materials offer exceptional chemical resistance, durability, mechanical properties, and fire performance to meet the application requirements. They can be manufactured in various weights and thicknesses to satisfy customer specifications. They have extensive applications in aerospace and defense, automotive, sports and leisure, and others with minimal use of materials and energy.

Market Dynamics

Market Drivers

Growing Demand from Aerospace Industry

Unidirectional tapes have a higher strength-to-weight ratio than other traditional aerospace materials. The use of UD tapes in aircraft accomplishes high strength, stiffness, and abrasion resistance. These tapes are used in both primary and secondary aircraft structures. UD tapes can be used in aircraft to increase the mechanical properties of a plastic part. The demand for aircraft is increasing globally, and the aerospace industry aims to introduce innovative solutions to improve manufacturing time and save costs.

According to the Boeing Commercial Outlook 2021-2040, Asia-Pacific (excluding China) will see approximately 8,945 new deliveries with a market service value of USD 1,945 billion by 2040. Therefore, the increasing number of aircraft deliverables is expected to elevate the manufacturing activities in the sector, which, in turn, is expected to drive the demand for unidirectional tape in the aerospace industry during the forecast period.

Rising Usage of Unidirectional Tape in Wind and Automotive Industries

Different reinforcement materials are used in unidirectional types like carbon fiber and glass fiber. Carbon fiber UD tape is driven by the soaring demand for lightweight materials in the automotive and wind energy industries. Unidirectional tapes are commonly utilized in the construction of wind turbines. The blades and rotators made from carbon fiber are used in windmills, significantly reducing the overall cost and increasing efficiency.

Carbon fiber composites, in general, are incrementally used in the automotive industry in parts such as battery boxes, leaf springs, pressure vessels, and others. The increased use of UD tapes in high-end cars and electric vehicles (EVs) is expected to enhance their market penetration in the automotive industry. The reduction in vehicle weight improves mileage and speed, and its use in EVs extends the car's range on a single charge. Several governments, including India, Australia, and Canada, are launching initiatives to promote e-vehicles, which will further drive the market of UD tape during the forecast period.

Market Restraint

High Manufacturing and Processing Costs 

There are many challenges confronting the unidirectional tape industry. Unidirectional tape is manufactured from glass or carbon fiber, embedded in a thermoplastic matrix, and specifically customized based on their different applications. The major raw material is glass and carbon fiber. Although carbon fiber has various advantages, several drawbacks of this material limit the scope of its applications significantly.

Additionally, the cost of this composite material is relatively high. Manufacturing unidirectional tape is a complicated process requiring advanced technical equipment. The price has decreased greatly in recent years but is still very expensive. Fiberglass is a very close relative to carbon fiber. Still, fiberglass is cheap by comparison, one of the major factors restraining the market's growth during the forecast period.

Market Opportunities

Growing Emphasis on Sustainability

A surging emphasis on sustainability and environmental responsibility is driving market revenue growth. The eco-friendliness of unidirectional tapes includes reduced material waste, energy efficiency during production, and recyclability. The shift toward sustainable practices in construction, consumer goods, and packaging generates a high demand for environmentally friendly materials. With their potential for lightweight construction and resource efficiency, unidirectional tapes align with the growing emphasis on sustainability, further creating opportunities for market growth.

Regional Analysis

Based on region, the global unidirectional tape market is bifurcated into North America, Europe, Asia-Pacific, South America, and the Middle East and Africa. 

Asia-Pacific unidirectional tape industry growth is projected to exhibit a CAGR of 10.63% during the forecast period. The market for unidirectional tapes in Asia-Pacific is expanding significantly. The region's rapid industrialization, growing investments in infrastructure development, and increasing adoption of advanced materials drive market demand. China, India, Japan, and South Korea significantly influence Asia-Pacific market expansion. In addition, the region's emphasis on sustainable construction practices, the rising demand for lightweight vehicles, and the presence of major manufacturing hubs all contribute to the development and use of unidirectional tapes in numerous industries.

Additionally, the surge in automotive sales in the region is further driving market growth. In 2021, the new vehicle sales in the Chinese market witnessed a year-on-year increase of 3.8%. According to the forecast by the China Association of Automobile Manufacturers (CAAM) in January 2022, the sales volume is anticipated to reach 27.5 million units. Moreover, the CAAM estimates that automobile production is further likely to ascend with the growing demand from the passenger cars segment. Thus driving the demand for unidirectional tapes.

Europe is expected to exhibit a CAGR of 10.11% over the forecast period. Europe's established manufacturing base, strong emphasis on sustainability, and technological advancements contribute to market expansion. Countries like Germany, the UK, and France are essential for market adoption. Increased health concerns will likely promote the adoption of sports and leisure activities. According to Statista, the sports equipment segment in Germany amounted to USD 2.87 billion in 2021. The industry is anticipated to grow at a CAGR of 3.18% from 2022 to 2026 and reach USD 3.58 billion in 2026. The rising demand for sports equipment will benefit the unidirectional tapes market over the forecast period. Additionally, Germany installed 1.92 GW of new onshore wind capacity in 2021, representing an increase of 35% compared to the previous year. Therefore, the country's expansion of wind energy projects to meet the climate goal is projected to further benefit the demand for unidirectional tapes.

In North America, the market for unidirectional tapes is anticipated to be significant. The region benefits from an advanced manufacturing infrastructure, a well-developed aerospace and automotive industry, and a lightweight and high-performance materials focus. The United States contributes significantly to the market due to its robust aerospace and defense sector, growing adoption of carbon fiber composites, and the presence of key market players. The Federal Aviation Administration (FAA) predicts that the total commercial aircraft fleet will reach 8,270 units in 2037 due to the increase in air cargo. Due to the aging of the existing fleet, the US mainliner carrier fleet is expected to expand to 54 aircraft per year. The US government allocated USD 768.2 billion for national defense programs in the 2022 defense budget, a 2% increase over the Biden administration's initial budget request, indicating an increase in the use of unidirectional tapes in the sector. Such factors from the aerospace sector drive the demand for unidirectional tapes in the North American region.

In Latin America, the market for unidirectional tapes presents promising opportunities. The region's expanding construction and automotive industries, rising investments in renewable energy, and growing emphasis on material innovation all contribute to the expansion of the market. Similarly, as of 2021, approximately 50 onshore wind projects have been planned for the next five years, with an investment of USD 12 billion. Growing technological improvements, such as high-efficiency wind turbines, have led companies to invest in the business. Countries such as Brazil, Mexico, and Argentina are essential to expanding the Latin American market. In addition, the region's emphasis on sustainable infrastructure projects, the growing use of composites in transportation, and the presence of major material manufacturers drive the use and adoption of unidirectional tapes in Latin America.

Segmental Analysis

The global unidirectional tape market is segmented by reinforcement type, backing material, adhesive type, and end-user industry.

Based on reinforcement type, the global unidirectional tape market is divided into glass fiber, carbon fiber, and other reinforcement types. 

The carbon fiber segment owns the highest market share and is expected to exhibit a CAGR of 10.57% throughout the forecast period. Carbon fibers are conductive and have a great mixture of high modulus and high tensile strength, a very low CTE, and good resistance to high temperatures. The carbon fiber unidirectional tapes are endless fiber-reinforced tapes of distinct widths with unidirectionally aligned reinforcing fibers in which carbon fibers are embedded in a thermoplastic matrix to produce different components. Carbon fiber unidirectional tapes can be processed in various ways. One of them is the tape-laying process. Consolidation units are often used after a laser has heated the UD tape and before it is placed in the component mold.

In addition, the unidirectional tapes are also amenable to so-called thermoforming. In this process, the material within a stenter frame is subjected to thermal energy through the utilization of compressed air, a vacuum, or a hydraulic press. This thermal energy causes the material to soften, facilitating its subsequent detachment. Subsequently, the material is compressed into the mold utilizing a pressing instrument.

Based on backing material, the global unidirectional tape market is divided into polyether ether ketone (PEEK), polyamide (PA), polypropylene (PP), polycarbonate (PC), polyphenylene sulfide (PPS), and other backing materials. 

The polyamide (PA) segment is the largest revenue contributor to the market and is predicted to exhibit a CAGR of 10.34% throughout the forecast period. Polyamide (PA) resins belong to the family of thermoplastic polymers (Nylon, Kevlar), meaning they can be formed with heat and remelted without losing their inherent properties. Polyamide resins are opaque, high-density polymers with excellent strength and heat tolerance. Compared with other polymers, polyamide stands up very well to higher temperatures. The two most important polyamides are polycaprolactam (Nylon 6) and poly (hexamethylene adipamide) (Nylon 6,6). Both have outstanding mechanical properties, including high flexibility, high tensile strength, good resilience, low creep, and high impact strength (toughness). Therefore, due to such properties, polyamide is widely used by companies for the production of unidirectional tapes.

Based on adhesive type, the global unidirectional tape market is bifurcated into epoxy, polyurethane, and other adhesive types. 

The polyurethane segment dominates the global market and is projected to exhibit a CAGR of 10.85% over the forecast period. Polyurethane (PU) resins are copolymers comprising polyol and isocyanate components. They are used as adhesives due to their excellent flexibility, followability, and adhesiveness. PU is a class of polymers composed of organic units joined by urethane links. Compared to other polymers, such as polyethylene and polystyrene, PU is manufactured from a wide range of precursor materials. This chemical variety produces PU with different chemical structures, leading to many applications.

Some of its applications include rigid and flexible foams, electrical potting compounds, varnishes and coatings, adhesives, and fibers such as spandex. According to Covestro estimates, the global demand for PU was estimated at around 21.32 million tons in 2022 and is expected to reach 22.4 million tons by 2024. Effective utility in adhesion applications in the automotive and aerospace industry is the major global driver for PU-based unidirectional tapes.

Based on the end-user industry, the global unidirectional tape market is segmented into aerospace and defense, automotive, sports and leisure, industrial, wind energy, and other industries. 

The aerospace and defense segment owns the highest market share and is anticipated to exhibit a CAGR of 10.46% during the forecast period. The aerospace and defense market includes revenues generated with sales of aircraft and their components, artillery tanks, weapons, radar, and other equipment used for aerospace and defense purposes. These tapes are employed in primary and secondary structures in aircraft. According to industry statistics, unidirectional tapes are used in aircraft seat frames as they decrease the weight of aircraft seats by approximately 30% compared to the traditional aluminum frame seats. Such reasons are estimated to drive the consumption of unidirectional tapes in the aerospace and defense industry.

Recent Developments

• January 2023- Asahi Kasei developed a new technology for recycling carbon fiber-reinforced plastic (CFRP) and carbon fiber-reinforced thermoplastics (CFRTP) used in automotive applications in collaboration with the National Institute of Technology, Kitakyushu College (Kyushu), and Tokyo University of Science. Additionally, Asahi Kasei is developing a CFRTP unidirectional (UD) tape made from recycled continuous carbon fiber and the company's Leona polyamide resin.
• January 2023- Victrex announced that the National Center for Advanced Materials Performance (NCAMP) had approved its new unidirectional tape (UDT), VICTREX AE™ 250-AS4, for use in aerospace programs.