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US Carbon Composites Market

ID: MRFR/CnM/14929-HCR
111 Pages
Chitranshi Jaiswal
October 2025

US Carbon Composites Market Research Report By Matrix (Hybrid, Metal, Ceramic, Carbon, Polymer) and By Process (Prepeg Layup Process, Pultrusion and Winding, Wet Lamination and Infusion Process, Press and Injection Processes, Other Processes) - Forecast to 2035.

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US Carbon Composites Market Summary

As per analysis, the US carbon composites market is projected to grow from USD 4.54 Billion in 2025 to USD 9.11 Billion by 2035, exhibiting a compound annual growth rate (CAGR) of 7.2% during the forecast period (2025 - 2035).

Key Market Trends & Highlights

The US carbon composites market is poised for substantial growth driven by technological advancements and increasing applications across various sectors.

  • The aerospace sector remains the largest segment, showcasing a robust demand for lightweight and high-strength materials.
  • Automotive applications are emerging as the fastest-growing segment, reflecting a shift towards more efficient and sustainable vehicle designs.
  • There is a notable focus on recycling and sustainability, as manufacturers seek to minimize environmental impact and enhance material lifecycle.
  • Technological advancements in manufacturing and government regulations are key drivers propelling the market forward.

Market Size & Forecast

2024 Market Size 4.24 (USD Billion)
2035 Market Size 9.11 (USD Billion)
CAGR (2025 - 2035) 7.2%

Major Players

Hexcel Corporation (US), Toray Industries, Inc. (JP), SGL Carbon SE (DE), Teijin Limited (JP), Mitsubishi Chemical Corporation (JP), Cytec Industries Inc. (US), Solvay S.A. (BE), BASF SE (DE), 3M Company (US)

US Carbon Composites Market Trends

The US carbon composites market is currently experiencing a notable transformation, driven by advancements in technology and increasing demand across various sectors. Industries such as aerospace, automotive, and construction are increasingly adopting carbon composites due to their lightweight properties and superior strength. This shift is indicative of a broader trend towards sustainability, as manufacturers seek materials that enhance performance while reducing environmental impact. Furthermore, the ongoing research and development efforts in the field are likely to yield innovative applications, further expanding the market's potential. In December 2025, the landscape of the US carbon composites market appears to be characterized by a growing emphasis on recycling and circular economy principles. Companies are exploring ways to repurpose carbon composite materials, which could lead to reduced waste and improved resource efficiency. Additionally, regulatory frameworks are evolving, potentially influencing production practices and material selection. As the market continues to mature, stakeholders may need to adapt to these changes to remain competitive and meet the demands of environmentally conscious consumers.

Increased Adoption in Aerospace Sector

The aerospace industry in the US is increasingly integrating carbon composites into aircraft design and manufacturing. This trend is driven by the need for lightweight materials that enhance fuel efficiency and performance. As airlines and manufacturers prioritize sustainability, carbon composites are becoming a preferred choice for new aircraft models.

Growth in Automotive Applications

The automotive sector is witnessing a surge in the use of carbon composites, particularly in high-performance vehicles. This trend reflects a broader industry shift towards lightweight materials that improve fuel economy and reduce emissions. As electric vehicles gain traction, the demand for carbon composites is likely to rise, supporting advancements in vehicle design.

Focus on Recycling and Sustainability

There is a growing emphasis on recycling carbon composites within the US market. Companies are exploring innovative methods to reclaim and reuse these materials, aligning with sustainability goals. This focus on circular economy practices may reshape production processes and influence material sourcing strategies in the coming years.

Market Segment Insights

By Application: Aerospace (Largest) vs. Automotive (Fastest-Growing)

In the US carbon composites market, the aerospace sector holds the largest share, driven by the increasing demand for lightweight materials that enhance fuel efficiency and performance in aircraft design. Following close behind, the automotive industry is rapidly adopting carbon composites, which are crucial for creating lighter vehicles that meet stringent emissions regulations while providing better performance and safety. Other applications, such as construction, sports equipment, and marine, contribute to the overall market yet lag behind the primary segments in terms of share.

Aerospace (Dominant) vs. Automotive (Emerging)

The aerospace segment remains dominant in the US carbon composites market, as manufacturers rely on these advanced materials for their superior strength-to-weight ratio, durability, and resistance to fatigue. Carbon composites are integral to aircraft structures, components, and interiors, ensuring optimal performance and compliance with industry regulations. In contrast, the automotive sector is recognized as an emerging field for carbon composites, where lightweight solutions are increasingly integrated into vehicle production to enhance efficiency and performance. This transition is fueled by the automotive industry's shift towards sustainability and innovation, positioning it as a fast-growing area, reflecting changing consumer preferences and regulatory imperatives.

By End Use: Structural Components (Largest) vs. Thermal Management (Fastest-Growing)

In the US carbon composites market, the end use segment showcases a diverse distribution of applications, with structural components leading in market share due to their extensive use in industries such as aerospace and automotive. Thermal management applications are rapidly gaining traction as they become vital for various electronic devices, highlighting a shift in market focus towards heat-resistant materials that ensure longevity and performance in increasingly demanding environments.

Structural Components: Aerospace (Dominant) vs. Thermal Management Systems (Emerging)

Structural components, particularly in aerospace, have established themselves as a dominant force in the US carbon composites market. These materials provide unmatched strength-to-weight ratios, enhancing fuel efficiency and performance in aircraft. In contrast, thermal management systems represent an emerging trend as more sectors adopt advanced composites to manage heat effectively, particularly in electric vehicles and consumer electronics. This shift is driven by the need for efficient thermal regulation, pushing innovation in composite manufacturing processes that enhance heat resistance and functionality.

By Type of Carbon Composite: Carbon Fiber Reinforced Polymer (Largest) vs. Carbon Nanotube Composites (Fastest-Growing)

In the US carbon composites market, Carbon Fiber Reinforced Polymer (CFRP) dominates due to its extensive use in aerospace, automotive, and sports equipment industries. Its lightweight and high strength contribute significantly to its widespread acceptance, making it a key player in composite applications. In contrast, Carbon Nanotube Composites, while currently a smaller segment, show a considerable growth trajectory driven by advancements in nanotechnology and increased demand in high-performance applications such as electronics and biomedical devices. Growth trends in the carbon composites market reveal a strong inclination toward materials that enhance performance while reducing weight. CFRP continues to benefit from the shift towards sustainable materials in manufacturing. Meanwhile, Carbon Nanotube Composites are emerging rapidly, fueled by their unique mechanical properties and potential for use in various innovative applications, thus attracting investment and research interest.

Carbon Fiber Reinforced Polymer (Dominant) vs. Carbon Nanotube Composites (Emerging)

Carbon Fiber Reinforced Polymer (CFRP) is characterized by its exceptional strength-to-weight ratio, making it a preferred choice for industries that require durability without adding significant weight, such as aerospace and automotive. The established infrastructure and manufacturing processes for CFRP further cement its dominant position in the US market. On the other hand, Carbon Nanotube Composites are emerging due to their unique electrical, thermal, and mechanical properties. Although still in the growth phase, they are being integrated into various applications ranging from consumer electronics to advanced materials in healthcare. As research progresses, the versatility and potential of Carbon Nanotube Composites may lead to greater market penetration, representing a significant opportunity for innovations in multiple sectors.

By Manufacturing Process: Layup (Largest) vs. Filament Winding (Fastest-Growing)

In the US carbon composites market, the manufacturing process segment has seen significant diversification with key processes such as layup, filament winding, pultrusion, and resin transfer molding each holding unique market shares. The layup process currently leads this segment due to its widespread adoption in various applications, offering versatility and ease of use for manufacturers. In contrast, filament winding has rapidly gained traction due to its efficiency in producing high-strength components, making it a crucial player in the market landscape.

Layup (Dominant) vs. Pultrusion (Emerging)

The layup process is the dominant manufacturing technique in the US carbon composites sector, celebrated for its flexibility and suitability for a variety of applications, including aerospace and automotive sectors. It allows manufacturers to create both simple and complex shapes efficiently. On the other hand, pultrusion is an emerging process known for its continuous production capabilities, particularly in creating long, uniform cross-sections. While it currently holds a smaller market share, pultrusion is gaining popularity due to advancements in technology that enhance speed and efficiency, coupled with its ability to produce components that meet high-performance standards.

Get more detailed insights about US Carbon Composites Market

Key Players and Competitive Insights

The carbon composites market is currently characterized by a dynamic competitive landscape, driven by increasing demand across various sectors such as aerospace, automotive, and renewable energy. Key players are actively pursuing strategies that emphasize innovation, sustainability, and technological advancement. For instance, Hexcel Corporation (US) has positioned itself as a leader in advanced composite materials, focusing on enhancing its product offerings through research and development. Similarly, Toray Industries, Inc. (JP) has been investing in expanding its production capabilities to meet the growing demand for lightweight materials, particularly in the automotive sector. These strategic initiatives collectively contribute to a competitive environment that is increasingly focused on technological differentiation and sustainability.

In terms of business tactics, companies are localizing manufacturing and optimizing supply chains to enhance operational efficiency. The market structure appears moderately fragmented, with several key players exerting significant influence. This fragmentation allows for a diverse range of products and innovations, while also fostering competition among established firms and new entrants alike. The collective influence of these key players shapes market dynamics, as they strive to capture market share through strategic partnerships and collaborations.

In November 2025, SGL Carbon SE (DE) announced a strategic partnership with a leading automotive manufacturer to develop next-generation carbon fiber components. This collaboration is expected to enhance SGL's position in the automotive sector, where lightweight materials are increasingly critical for improving fuel efficiency and reducing emissions. The partnership underscores the importance of aligning with industry leaders to drive innovation and meet evolving market demands.

In October 2025, Cytec Industries Inc. (US) launched a new line of bio-based carbon composites aimed at reducing environmental impact. This initiative reflects a growing trend towards sustainability within the industry, as companies seek to address consumer preferences for eco-friendly products. By diversifying its product portfolio, Cytec is likely to strengthen its competitive edge and appeal to a broader customer base.

In September 2025, Solvay S.A. (BE) expanded its production facility in the US to increase output of high-performance carbon composites. This expansion is indicative of Solvay's commitment to meeting the rising demand for advanced materials in aerospace and defense applications. The strategic move not only enhances production capacity but also positions Solvay to better serve its customers in a rapidly evolving market.

As of December 2025, current trends in the carbon composites market are heavily influenced by digitalization, sustainability, and the integration of artificial intelligence (AI) in manufacturing processes. Strategic alliances are becoming increasingly vital, as companies recognize the need to collaborate to leverage technological advancements and enhance product offerings. Looking ahead, competitive differentiation is likely to evolve from traditional price-based competition to a focus on innovation, technology, and supply chain reliability. This shift suggests that companies that prioritize R&D and sustainable practices will be better positioned to thrive in the future.

Key Companies in the US Carbon Composites Market market include

Industry Developments

The US Carbon Composites Market has experienced notable developments recently. Companies like Kordsa Teknik Tekstil A.S. and Toray Industries have been investing in advanced manufacturing processes to enhance the structural integrity of carbon composites, reflecting ongoing innovations in the industry. In August 2023, Hexcel announced the expansion of its production capabilities in the US to meet rising demand from aerospace applications, particularly from major clients like Boeing. Additionally, Solvay has reported advancements in sustainable carbon fiber technologies, aiming to reduce the environmental footprint of composite materials.

Mergers and acquisitions have also been significant, with Northrop Grumman acquiring Zoltek Companies in July 2023 to strengthen its position in carbon fiber production, while Cytec Solvay Group integrated advanced composite solutions to enhance its service offerings. The market has shown growth potential, with a valuation increase driven by robust demand from aerospace, automotive, and industrial sectors, which indicates a thriving landscape for key players like General Electric and Mitsubishi Chemical Corporation. The dynamics in the market remain positive, spurred by investments in Research and Development and strategic collaborations among these core companies.

Future Outlook

US Carbon Composites Market Future Outlook

The US carbon composites market is projected to grow at a 7.2% CAGR from 2024 to 2035, driven by advancements in aerospace, automotive, and renewable energy sectors.

New opportunities lie in:

  • Development of lightweight carbon composite materials for electric vehicles
  • Expansion of carbon composite applications in wind turbine manufacturing
  • Investment in recycling technologies for carbon composites to enhance sustainability

By 2035, the market is expected to achieve substantial growth, driven by innovation and increased demand.

Market Segmentation

US Carbon Composites Market End Use Outlook

  • Structural Components
  • Thermal Management
  • Electrical Components
  • Protective Equipment
  • Consumer Goods

US Carbon Composites Market Application Outlook

  • Aerospace
  • Automotive
  • Construction
  • Sports Equipment
  • Marine

US Carbon Composites Market Manufacturing Process Outlook

  • Layup
  • Filament Winding
  • Pultrusion
  • Resin Transfer Molding

US Carbon Composites Market Type of Carbon Composite Outlook

  • Carbon Fiber Reinforced Polymer
  • Carbon Nanotube Composites
  • Carbon Fiber Reinforced Metal
  • Carbon Fiber Reinforced Concrete

Report Scope

MARKET SIZE 20244.24(USD Billion)
MARKET SIZE 20254.54(USD Billion)
MARKET SIZE 20359.11(USD Billion)
COMPOUND ANNUAL GROWTH RATE (CAGR)7.2% (2024 - 2035)
REPORT COVERAGERevenue Forecast, Competitive Landscape, Growth Factors, and Trends
BASE YEAR2024
Market Forecast Period2025 - 2035
Historical Data2019 - 2024
Market Forecast UnitsUSD Billion
Key Companies ProfiledHexcel Corporation (US), Toray Industries, Inc. (JP), SGL Carbon SE (DE), Teijin Limited (JP), Mitsubishi Chemical Corporation (JP), Cytec Industries Inc. (US), Solvay S.A. (BE), BASF SE (DE), 3M Company (US)
Segments CoveredApplication, End Use, Type of Carbon Composite, Manufacturing Process
Key Market OpportunitiesGrowing demand for lightweight materials in aerospace and automotive sectors drives US carbon composites market expansion.
Key Market DynamicsRising demand for lightweight materials drives innovation and competition in the US carbon composites market.
Countries CoveredUS

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FAQs

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

The US Carbon Composites Market is expected to be valued at 4.5 USD Billion in 2024.

What is the projected market size of the US Carbon Composites Market by 2035?

By 2035, the US Carbon Composites Market is projected to reach a value of 11.0 USD Billion.

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

The market is expected to grow at a CAGR of 8.465% during the period from 2025 to 2035.

Which segment is expected to have the largest market value in 2035?

The Hybrid segment is expected to dominate the market, valued at 2.7 USD Billion in 2035.

What are the expected growth rates for the different matrix segments in the US Carbon Composites Market by 2035?

By 2035, the Hybrid, Metal, Ceramic, Carbon, and Polymer segments are expected to reach 2.7 USD Billion, 2.2 USD Billion, 1.5 USD Billion, 3.5 USD Billion, and 1.1 USD Billion respectively.

Who are the major players in the US Carbon Composites Market?

Some of the key players include Celanese Corporation, Honeywell International, Boeing, Northrop Grumman, and General Electric.

Which company is anticipated to have a significant presence in the Carbon segment by 2035?

The Carbon segment is projected to reach 3.5 USD Billion in market value by 2035, indicating strong competition.

What applications are driving the growth of the US Carbon Composites Market?

Key applications include aerospace, automotive, and defense sectors, which are fueling market expansion.

What challenges could impact the US Carbon Composites Market from 2025 to 2035?

Challenges include high manufacturing costs and competition from alternative materials in the market.

How is the US Carbon Composites Market expected to evolve in terms of regionality by 2035?

The market is expected to grow significantly in regions with strong aerospace and automotive industries.

What is the expected CAGR for the US Carbon Composites Market from 2025 to 2035?

The expected CAGR for the US Carbon Composites Market from 2025 to 2035 is 8.007%.

Which segment is expected to have the largest market share in 2024?

In 2024, the Hybrid segment is expected to hold the largest market share, valued at 1.0 USD Billion.

What are the market values of the Ceramic segment in 2024 and 2035?

The Ceramic segment is valued at 0.6 USD Billion in 2024 and is expected to reach 1.5 USD Billion by 2035.

Who are the key players in the US Carbon Composites Market?

Key players in the US Carbon Composites Market include Kordsa Teknik Tekstil A.S., Toray Industries, and Hexcel, among others.

What is the expected market value of the Carbon segment in 2035?

The Carbon segment is expected to reach a market value of 2.6 USD Billion by 2035.

How does the Metal segment's market value compare between 2024 and 2035?

The Metal segment's market value is projected to increase from 0.9 USD Billion in 2024 to 2.2 USD Billion in 2035.

What are some key trends driving the growth of the US Carbon Composites Market?

Key trends include the growing demand for lightweight materials and advancements in composite manufacturing technologies.

What market value is projected for the Polymer segment by 2035?

The Polymer segment is projected to reach a market value of 1.7 USD Billion by 2035.

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