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US Aerostructures Market

ID: MRFR/AD/17535-HCR
100 Pages
Garvit Vyas
October 2025

US Aerostructures Market Research Report: By Component (Fuselage, Flight Control Surfaces, Wings, Nose, Nacelle and Pylon, Others), By Material (Composite, Alloys, Metals), By End-Use (OEM, Aftermarket) and By Platform (Fixed Wing, Rotary Wing) - Forecast to 2035

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US Aerostructures Market Infographic
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US Aerostructures Market Summary

As per analysis, the US aerostructures market is projected to grow from USD 532.0 Million in 2025 to USD 1,197.0 Million by 2035, exhibiting a compound annual growth rate (CAGR) of 8.15% during the forecast period (2025 - 2035).

Key Market Trends & Highlights

The US aerostructures market is poised for growth driven by sustainability and technological advancements.

  • The commercial aviation segment remains the largest contributor to the US aerostructures market, reflecting a robust demand for air travel.
  • Military aviation is the fastest-growing segment, fueled by increased defense spending and modernization efforts.
  • Aluminum continues to dominate as the primary material used in aerostructures, while composite materials are rapidly gaining traction due to their lightweight properties.
  • Key market drivers include increased defense spending and regulatory support for innovation, which are likely to shape future developments.

Market Size & Forecast

2024 Market Size 505.4 (USD Million)
2035 Market Size 1197.0 (USD Million)
CAGR (2025 - 2035) 8.15%

Major Players

Boeing (US), Lockheed Martin (US), Northrop Grumman (US), Raytheon Technologies (US), General Dynamics (US), Spirit AeroSystems (US), Textron (US), Hawker Beechcraft (US), L3Harris Technologies (US)

US Aerostructures Market Trends

The US aerostructures market is currently experiencing a transformative phase, driven by advancements in technology and increasing demand for more efficient aircraft. The integration of lightweight materials and innovative manufacturing processes appears to be reshaping the landscape, enabling manufacturers to produce components that enhance performance while reducing operational costs. Furthermore, the emphasis on sustainability is prompting companies to explore eco-friendly materials and practices, aligning with broader environmental goals. This shift not only addresses regulatory pressures but also caters to the evolving preferences of consumers and stakeholders alike. In addition, the US aerostructures market is witnessing a surge in investment aimed at modernization and expansion of production capabilities. As the aerospace sector continues to recover and grow, there is a notable focus on enhancing supply chain resilience. This trend suggests that companies are prioritizing strategic partnerships and collaborations to ensure a steady flow of materials and components. Overall, the current dynamics within the US aerostructures market indicate a robust trajectory, characterized by innovation, sustainability, and strategic growth initiatives.

Sustainability Initiatives

The US aerostructures market is increasingly prioritizing sustainability, with manufacturers adopting eco-friendly materials and processes. This trend reflects a commitment to reducing environmental impact while meeting regulatory requirements. Companies are exploring alternative materials that offer lower carbon footprints, which may enhance their competitive edge in a market that values environmental responsibility.

Technological Advancements

Technological innovation is a driving force in the US aerostructures market, with advancements in manufacturing techniques such as additive manufacturing and automation. These technologies enable the production of complex components with greater precision and efficiency. As a result, manufacturers are likely to achieve cost savings and improved product performance, positioning themselves favorably in a competitive landscape.

Supply Chain Resilience

The focus on supply chain resilience is becoming increasingly prominent within the US aerostructures market. Companies are recognizing the importance of establishing robust supply chains to mitigate risks associated with disruptions. This trend may lead to strategic partnerships and investments in local sourcing, ultimately enhancing the reliability and efficiency of production processes.

Market Segment Insights

By Application: Commercial Aviation (Largest) vs. Military Aviation (Fastest-Growing)

The US aerostructures market is primarily segmented into Commercial Aviation, Military Aviation, Space Exploration, Unmanned Aerial Vehicles, and Helicopters. In this landscape, Commercial Aviation holds the largest share, driven by the high demand for air travel and the continuous development of new aircraft models. Meanwhile, Military Aviation is positioned as a vital part of national defense, maintaining a substantial market presence due to ongoing government funding and modernization initiatives.

Commercial Aviation (Dominant) vs. Military Aviation (Emerging)

Commercial Aviation remains a dominant force within the US aerostructures market, characterized by high production rates, extensive supply chains, and the constant evolution of aerospace technology. This segment thrives on large-scale aircraft production, focusing on fuel efficiency and passenger comfort. Conversely, Military Aviation has emerged as a critical growth area, spurred by increasing defense budgets and the need for advanced military capabilities. The emphasis on unmanned systems and advanced materials highlights a shift towards modernization in military aircraft, creating a dynamic market characterized by innovation and changing defense strategies.

By Material Type: Aluminum (Largest) vs. Composite Materials (Fastest-Growing)

In the US aerostructures market, the material types have distinct market shares, with aluminum leading significantly due to its favorable properties such as lightweight, high strength, and resistance to corrosion. Following aluminum are composite materials, which are gaining traction for their excellent strength-to-weight ratio, making them increasingly popular for modern aircraft designs. Titanium, steel, and magnesium follow, each holding niche positions in the market, often based on specific application requirements and performance attributes. The growth trends within the material type segment show a clear shift toward composite materials as aerospace manufacturers seek ways to enhance fuel efficiency and reduce overall weight. This demand is driven by stringent emission regulations and the need for improved performance in next-generation aircraft. While aluminum remains a staple, innovations in composite fabrication and processing are positioning them as the material of choice for many manufacturers, indicating a significant transformation in the industry.

Aluminum (Dominant) vs. Composite Materials (Emerging)

Aluminum is the dominant material in the US aerostructures market, known for its balance of performance, weight, and cost-effectiveness. It is extensively used for aircraft fuselage, wings, and other structural components, thus holding a significant market position. With its long history in aerospace applications, aluminum benefits from established manufacturing processes and supply chains. On the other hand, composite materials are the emerging player in the market, favored for their exceptional strength-to-weight ratio and fatigue resistance. Their increasing adoption is fueled by advancements in manufacturing techniques and materials science, leading to reduced cycle times and costs. While aluminum continues to be prevalent, the shift towards composites indicates a transformative trend in aerostructures, with aerospace engineers aiming for lightweight designs without compromising structural integrity.

By End Use: Airframe (Largest) vs. Wing Structures (Fastest-Growing)

In the US aerostructures market, the end use segment is primarily dominated by the airframe segment, which commands a substantial share due to its critical role in aircraft assembly. The airframe, serving as the backbone of the aircraft, integrates various structures, ensuring both performance and safety. Meanwhile, wing structures are undergoing rapid growth as they become increasingly complex and integral to modern aircraft design, leading to innovations in lightweight materials and aerodynamic efficiencies.

Airframe (Dominant) vs. Wing Structures (Emerging)

The airframe segment remains dominant within the US aerostructures market, being responsible for the major structural elements that support the aircraft's functionality. Its established presence is bolstered by consistent demand from both commercial and military aircraft sectors. Conversely, wing structures are emerging as a vital component due to advancements in design and materials, focusing on enhancing fuel efficiency and performance. With increasing competition in the aerospace sector, manufacturers are prioritizing innovative wing designs to improve overall aircraft capabilities, positioning wing structures as a crucial area for future investment and development.

Get more detailed insights about US Aerostructures Market

Key Players and Competitive Insights

The aerostructures market in the US is characterized by a competitive landscape that is both dynamic and multifaceted. Key growth drivers include advancements in aerospace technology, increasing demand for fuel-efficient aircraft, and a robust defense sector. Major players such as Boeing (US), Lockheed Martin (US), and Northrop Grumman (US) are strategically positioned to leverage these trends. Boeing (US) focuses on innovation and sustainability, particularly in developing next-generation aircraft components. Lockheed Martin (US) emphasizes defense contracts and advanced manufacturing techniques, while Northrop Grumman (US) is heavily invested in digital transformation and automation. Collectively, these strategies not only enhance their operational capabilities but also shape a competitive environment that is increasingly reliant on technological advancements and strategic partnerships.

In terms of business tactics, companies are localizing manufacturing to reduce lead times and optimize supply chains. This approach is particularly evident in the moderately fragmented market structure, where key players exert considerable influence. The collective actions of these companies suggest a trend towards consolidation, as they seek to enhance their competitive edge through strategic mergers and acquisitions, thereby streamlining operations and expanding their market reach.

In November 2025, Boeing (US) announced a partnership with a leading technology firm to develop advanced composite materials aimed at reducing aircraft weight and improving fuel efficiency. This strategic move underscores Boeing's commitment to innovation and sustainability, positioning the company to meet the evolving demands of the aerospace sector. The collaboration is expected to yield significant advancements in aerostructure design, potentially setting new industry standards.

In October 2025, Lockheed Martin (US) secured a substantial contract with the US Department of Defense for the production of advanced aerostructures for military aircraft. This contract not only reinforces Lockheed Martin's position in the defense sector but also highlights the company's focus on leveraging cutting-edge manufacturing technologies. The strategic importance of this contract lies in its potential to enhance operational efficiency and reduce production costs, thereby solidifying Lockheed Martin's competitive advantage.

In September 2025, Northrop Grumman (US) unveiled a new digital manufacturing facility aimed at integrating AI and automation into its production processes. This facility is expected to significantly enhance production capabilities and reduce time-to-market for new aerostructures. The strategic importance of this initiative lies in its potential to drive innovation and improve supply chain reliability, which are critical factors in maintaining competitiveness in the rapidly evolving aerospace market.

As of December 2025, current competitive trends in the aerostructures market are increasingly defined by digitalization, sustainability, and AI integration. Strategic alliances are becoming more prevalent, as companies recognize the need to collaborate in order to innovate and meet regulatory demands. The competitive landscape is shifting from traditional price-based competition to a focus on technological differentiation and supply chain resilience. This evolution suggests that companies that prioritize innovation and reliability in their operations will likely emerge as leaders in the market.

Key Companies in the US Aerostructures Market market include

Industry Developments

The US Aerostructures Market has witnessed significant developments recently, with companies like Boeing and Lockheed Martin expanding their production capabilities to meet rising demand. In September 2023, General Dynamics announced a major contract win with the US government to supply advanced aerostructures, reinforcing its position in the defense sector. Meanwhile, Safran and Honeywell are collaborating on innovative technologies to enhance fuel efficiency in next-generation aircraft. Recent trends indicate a strong growth trajectory, partly fueled by an uptick in commercial aviation as travel demand rebounds post-pandemic.

In terms of mergers and acquisitions, Triumph Group completed the acquisition of a major aerostructures manufacturer in August 2023, aiming to bolster its market share and service offerings. Additionally, Rockwell Collins expanded its operations in the US by acquiring a cutting-edge technology firm in the aeronautics field in July 2023, highlighting the ongoing consolidation in the market. Over the past two years, companies have reported a steady increase in revenues, aligning with the overall growth forecast for the US aerostructures sector, which is projected to further accelerate as the industry adapts to emerging technologies and infrastructure investments.

Future Outlook

US Aerostructures Market Future Outlook

The US aerostructures market is poised for growth at 8.15% CAGR from 2024 to 2035, driven by technological advancements, increased defense spending, and rising demand for fuel-efficient aircraft.

New opportunities lie in:

  • Investment in advanced composite materials for lightweight structures.
  • Development of modular aerostructures for rapid assembly and maintenance.
  • Expansion into unmanned aerial vehicle (UAV) aerostructures for defense applications.

By 2035, the US aerostructures market is expected to achieve robust growth and innovation.

Market Segmentation

US Aerostructures Market End Use Outlook

  • Airframe
  • Wing Structures
  • Fuselage
  • Empennage
  • Control Surfaces

US Aerostructures Market Application Outlook

  • Commercial Aviation
  • Military Aviation
  • Space Exploration
  • Unmanned Aerial Vehicles
  • Helicopters

US Aerostructures Market Material Type Outlook

  • Aluminum
  • Composite Materials
  • Titanium
  • Steel
  • Magnesium

Report Scope

MARKET SIZE 2024505.4(USD Million)
MARKET SIZE 2025532.0(USD Million)
MARKET SIZE 20351197.0(USD Million)
COMPOUND ANNUAL GROWTH RATE (CAGR)8.15% (2024 - 2035)
REPORT COVERAGERevenue Forecast, Competitive Landscape, Growth Factors, and Trends
BASE YEAR2024
Market Forecast Period2025 - 2035
Historical Data2019 - 2024
Market Forecast UnitsUSD Million
Key Companies ProfiledBoeing (US), Lockheed Martin (US), Northrop Grumman (US), Raytheon Technologies (US), General Dynamics (US), Spirit AeroSystems (US), Textron (US), Hawker Beechcraft (US), L3Harris Technologies (US)
Segments CoveredApplication, Material Type, End Use
Key Market OpportunitiesAdvancements in lightweight materials enhance efficiency in the US aerostructures market.
Key Market DynamicsTechnological advancements and regulatory changes drive innovation and competition in the US aerostructures market.
Countries CoveredUS

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FAQs

What is the expected market size of the US Aerostructures Market in 2024?

The US Aerostructures Market is expected to be valued at 8.0 USD Billion in 2024.

What will be the projected market size for the US Aerostructures Market by 2035?

By 2035, the US Aerostructures Market is projected to reach a value of 26.0 USD Billion.

What is the expected compound annual growth rate (CAGR) for the US Aerostructures Market from 2025 to 2035?

The expected CAGR for the US Aerostructures Market from 2025 to 2035 is 11.31%.

Which component has the highest market value in the US Aerostructures Market for 2024?

The fuselage component is valued at 2.5 USD Billion in the US Aerostructures Market for 2024.

What market value is anticipated for the flight control surfaces component by 2035?

The flight control surfaces component is expected to be valued at 4.0 USD Billion by 2035.

Who are the key players in the US Aerostructures Market?

Major players in the US Aerostructures Market include Raytheon Technologies, Boeing, Lockheed Martin, and General Dynamics among others.

What is the market value for wings in the US Aerostructures Market in 2024?

In 2024, the wings segment of the US Aerostructures Market is valued at 2.0 USD Billion.

What are the expected challenges facing the US Aerostructures Market growth?

Challenges include supply chain disruptions and increasing material costs affecting market stability.

What is the projected value of the nose component in the US Aerostructures Market by 2035?

The nose component is projected to reach a market value of 3.5 USD Billion by 2035.

What is the market value for nacelle and pylon in 2024?

The nacelle and pylon segment holds a market value of 1.3 USD Billion in 2024.

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