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US Thermoplastic Composites Market

ID: MRFR/CnM/18858-HCR
200 Pages
Chitranshi Jaiswal
October 2025

US Thermoplastic Composites Market Research Report By Resin Type (Polyamide, Polypropylene, PEEK, Hybrid, Others), By Fiber Type (Glass Fiber, Carbon Fiber, Others), By Product Type (SFT, LFT, CFT, GMT) and By Application (Aerospace Défense, Automotive Transportation, Consumer Goods, Others) - Forecast to 2035

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US Thermoplastic Composites Market Summary

As per analysis, the US thermoplastic composites market is projected to grow from USD 4.69 Million in 2024 to USD 11.3 Million by 2035, exhibiting a compound annual growth rate (CAGR) of 8.31% during the forecast period (2025 - 2035).

Key Market Trends & Highlights

The US thermoplastic composites market is poised for robust growth driven by sustainability and technological advancements.

  • The aerospace segment remains the largest contributor to the thermoplastic composites market, reflecting its established applications and demand.
  • The automotive sector is the fastest-growing segment, driven by increasing adoption of lightweight materials for enhanced fuel efficiency.
  • Structural components dominate the market, while electrical components are emerging as the fastest-growing category due to rising electrification trends.
  • Key market drivers include sustainability initiatives and technological advancements, which are shaping the future of thermoplastic composites.

Market Size & Forecast

2024 Market Size 4.69 (USD Million)
2035 Market Size 11.3 (USD Million)
CAGR (2025 - 2035) 8.31%

Major Players

Toray Industries (JP), BASF (DE), SABIC (SA), Solvay (BE), Mitsubishi Chemical (JP), Teijin Limited (JP), Hexcel Corporation (US), Celanese Corporation (US), DuPont (US)

US Thermoplastic Composites Market Trends

The US thermoplastic composites market is currently experiencing a notable transformation, driven by advancements in material science and increasing demand across various industries. These composites, known for their lightweight and durable properties, are becoming increasingly popular in sectors such as automotive, aerospace, and construction. The shift towards sustainable materials is also influencing market dynamics, as manufacturers seek to reduce environmental impact while maintaining performance standards. As a result, the market landscape is evolving, with new applications and innovations emerging regularly. In December 2025, the US thermoplastic composites market appears poised for further growth, as companies invest in research and development to enhance product offerings. The integration of advanced manufacturing techniques, such as additive manufacturing and automated processes, is likely to streamline production and improve efficiency. Additionally, collaborations between industry players and research institutions may foster innovation, leading to the development of next-generation composites that meet the specific needs of various applications. Overall, the market is characterized by a blend of traditional practices and cutting-edge technologies, suggesting a promising future for thermoplastic composites in the United States.

Sustainability Initiatives

The US thermoplastic composites market is increasingly influenced by sustainability initiatives. Manufacturers are focusing on developing eco-friendly materials and processes to minimize environmental impact. This trend aligns with broader industry goals to reduce carbon footprints and promote recycling, which is becoming a priority for many companies.

Technological Advancements

Technological advancements are reshaping the US thermoplastic composites market. Innovations in manufacturing techniques, such as automated processes and additive manufacturing, are enhancing production efficiency and product quality. These developments enable the creation of more complex geometries and tailored properties, catering to diverse industry needs.

Growing Demand in Automotive Sector

The automotive sector is driving significant demand within the US thermoplastic composites market. As manufacturers strive to produce lighter and more fuel-efficient vehicles, thermoplastic composites offer an attractive solution. This trend is likely to continue as the industry shifts towards electric and hybrid vehicles, which require advanced materials for optimal performance.

Market Segment Insights

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

In the US thermoplastic composites market, the application segment showcases a diverse distribution among aerospace, automotive, consumer goods, electronics, and industrial fields. Aerospace leads the market as the largest segment, demonstrating a significant share due to the industry’s demand for lightweight and durable materials that enhance fuel efficiency and performance in aircraft structures. The automotive sector is close behind, gaining traction as manufacturers increasingly adopt thermoplastic composites for vehicle components to improve safety and reduce weight. The growth trends within the application segment are heavily influenced by the continuous push for innovation and sustainability across industries. The aerospace sector continues to expand due to advancements in manufacturing technologies that lower production costs. On the other hand, the automotive segment is the fastest-growing, driven by the rise in electric vehicles and regulatory commitments to reduce emissions, which necessitate the use of innovative lightweight materials like thermoplastic composites.

Aerospace: Dominant vs. Automotive: Emerging

Aerospace remains the dominant application of thermoplastic composites in the US market, primarily due to its impressive performance characteristics, including high strength-to-weight ratios and resistance to environmental stressors. This sector requires materials that can withstand extreme conditions while contributing to overall vehicle efficiency. Aerospace companies are increasingly integrating thermoplastic composites into airframe components and interior fittings to enhance durability. In contrast, the automotive sector is emerging as a vital application area as it accelerates toward a more sustainable future. Automotive manufacturers are recognizing the benefits of thermoplastic composites not only for reducing weight but also for enhancing design flexibility and production efficiency. This growing sector is characterized by significant investment in research and development to explore innovative applications that will fulfill industry needs.

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

In the US thermoplastic composites market, structural components represent the largest segment, widely utilized across various industries including automotive, aerospace, and construction. These components play a critical role in enhancing strength while reducing overall weight, leading to improved fuel efficiency and performance. Following structural components, electrical components are gaining momentum due to the increasing demand for lightweight and durable materials to support advanced electronic systems in vehicles and devices. The growth trends for these segments indicate a significant shift towards sustainable and lightweight solutions. Factors driving the popularity of structural components include stringent regulations on emissions and the need for energy efficiency. Conversely, electrical components are emerging rapidly, propelled by advancements in technology and a rise in electric vehicle production. This trend points to a promising future for thermoplastic composites, especially in applications that require superior electrical properties and greater design flexibility.

Structural Components (Dominant) vs. Electrical Components (Emerging)

Structural components remain the dominant force in the US thermoplastic composites market due to their versatility and performance advantages. These components are characterized by their ability to withstand substantial mechanical stresses while maintaining low weight, making them ideal for applications in automotive frames and aircraft fuselages. On the other hand, electrical components are fast emerging as a key player, driven primarily by the growth of the electric vehicle sector and the increasing reliance on high-performance materials in consumer electronics. As manufacturers continue to innovate in the realm of lightweight composites with enhanced electrical properties, the electrical components segment is expected to capture greater market attention, leading to a well-balanced competition between these two segments.

By Material Type: Polypropylene (Largest) vs. Polyamide (Fastest-Growing)

In the US thermoplastic composites market, the material type segment is primarily dominated by polypropylene, which is the most widely used due to its excellent mechanical properties, lightweight nature, and cost-effectiveness. Following closely is polyamide, gaining traction in various applications due to its superior thermal stability and resilience against impact. Polycarbonate and polyethylene also contribute to the market but hold smaller shares compared to the leadership of polypropylene and the rising popularity of polyamide.

Polypropylene (Dominant) vs. Polyamide (Emerging)

Polypropylene has established itself as the dominant material in the thermoplastic composites market because of its favorable attributes such as lightweight composition, flexibility, and robust mechanical performance. It is widely used in automotive, consumer goods, and industrial applications. On the other hand, polyamide is emerging rapidly due to its enhanced strength, durability, and chemical resistance, making it a preferred choice in high-performance applications like aerospace and automotive. As manufacturers prioritize lightweight yet strong materials, the demand for polyamide is projected to grow, indicating a shift in market dynamics where emerging materials could challenge traditional leaders.

By Manufacturing Process: Injection Molding (Largest) vs. Compression Molding (Fastest-Growing)

In the US thermoplastic composites market, Injection Molding holds the largest market share due to its widespread application in various industries, including automotive and consumer goods. This method is highly favored for its efficiency and versatility, allowing manufacturers to create complex shapes with high precision. Conversely, Compression Molding, while representing a smaller market share, is gaining traction as it is increasingly adopted in sectors such as aerospace and electronics where lightweight and durable components are in demand.

Manufacturing Process: Injection Molding (Dominant) vs. Compression Molding (Emerging)

Injection Molding is the dominant manufacturing process for thermoplastic composites in the US market, renowned for its ability to produce high volumes of parts with intricate designs rapidly. It caters mainly to the automotive sector, providing lightweight yet robust components that enhance fuel efficiency. On the other hand, Compression Molding, though emerging, is witnessing a surge in popularity due to its lower material waste and suitability for large, flat components, particularly in industries focused on sustainability and advanced composites, thereby positioning itself as a viable alternative as the market evolves.

By Reinforcement Type: Glass Fiber (Largest) vs. Carbon Fiber (Fastest-Growing)

In the US thermoplastic composites market, glass fiber remains the largest reinforcement type due to its widespread use in various industries, including automotive and construction. Its advantageous properties such as low cost, high strength-to-weight ratio, and excellent durability contribute to its market dominance. Carbon fiber is rapidly gaining ground, particularly in high-performance applications, owing to its superior mechanical properties and lightweight nature, making it desirable for sectors focused on reducing weight and enhancing performance. The growth trends in the reinforcement type segment are significantly influenced by advancements in manufacturing techniques and an increasing demand for lightweight materials. Carbon fiber, recognized as the fastest-growing reinforcement type, is expected to benefit from a broader adoption in automotive and aerospace industries. Furthermore, natural and aramid fibers are gradually gaining traction as they align with sustainability and eco-friendly trends, reflecting a shift towards innovative and green composite solutions.

Glass Fiber (Dominant) vs. Carbon Fiber (Emerging)

Glass fiber is known for its cost-effectiveness and versatility, making it the dominant reinforcement type in the US thermoplastic composites market. It is primarily used in applications like automotive components and construction materials due to its reliable performance and established manufacturing processes. In contrast, carbon fiber is emerging as a highly desirable option due to its exceptional strength and lightweight characteristics, demonstrating remarkable performance in aerospace, automotive, and sporting goods. This shift is driven by the need for improved fuel efficiency and performance in high-end applications. With ongoing advancements in production methods, such as automated prepregging and RTM, carbon fiber is becoming more accessible, paving the way for growth in various sectors.

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Key Players and Competitive Insights

The thermoplastic composites market is currently characterized by a dynamic competitive landscape, driven by increasing demand for lightweight materials across various industries, including automotive, aerospace, and consumer goods. Key players such as Toray Industries (Japan), BASF (Germany), and Hexcel Corporation (US) are strategically positioned to leverage innovation and sustainability in their operations. Toray Industries (Japan) focuses on enhancing its product portfolio through advanced research and development, while BASF (Germany) emphasizes partnerships to expand its market reach. Hexcel Corporation (US) is actively pursuing digital transformation initiatives to optimize its manufacturing processes, collectively shaping a competitive environment that prioritizes technological advancement and sustainability.

In terms of business tactics, companies are increasingly localizing manufacturing to reduce lead times and enhance supply chain resilience. The market appears moderately fragmented, with several key players exerting influence over specific segments. This structure allows for a diverse range of offerings, yet the collective strength of major companies like SABIC (Saudi Arabia) and Solvay (Belgium) ensures that competition remains robust, fostering innovation and efficiency.

In November 2025, SABIC (Saudi Arabia) announced a strategic partnership with a leading automotive manufacturer to develop next-generation thermoplastic composites aimed at reducing vehicle weight and enhancing fuel efficiency. This collaboration underscores SABIC's commitment to sustainability and innovation, positioning the company as a frontrunner in the automotive sector. The partnership is likely to yield significant advancements in material performance, aligning with industry trends towards eco-friendly solutions.

In October 2025, Solvay (Belgium) unveiled a new line of thermoplastic composite materials designed specifically for aerospace applications, emphasizing their lightweight and high-strength properties. This launch reflects Solvay's strategic focus on expanding its footprint in the aerospace market, where demand for advanced materials is surging. The introduction of these materials could potentially enhance aircraft performance and fuel efficiency, further solidifying Solvay's competitive edge.

In September 2025, Hexcel Corporation (US) completed the acquisition of a technology firm specializing in AI-driven manufacturing solutions. This acquisition is indicative of Hexcel's strategy to integrate cutting-edge technology into its production processes, enhancing efficiency and reducing costs. The move is expected to bolster Hexcel's position in the thermoplastic composites market by enabling faster production cycles and improved product quality.

As of December 2025, current competitive trends in the thermoplastic composites market are increasingly defined by digitalization, sustainability, and the integration of AI technologies. Strategic alliances are becoming more prevalent, as companies recognize the value of collaboration in driving innovation and market expansion. Looking ahead, competitive differentiation is likely to evolve from traditional price-based competition towards a focus on technological innovation, supply chain reliability, and sustainable practices, reflecting the industry's shift towards more responsible and efficient manufacturing processes.

Key Companies in the US Thermoplastic Composites Market market include

Industry Developments

Recent developments in the US Thermoplastic Composites Market indicate a burgeoning interest in sustainable materials, driven by companies such as SABIC and Mitsubishi Chemical Corporation, which are expanding their research efforts into greener thermoplastic options. In September 2023, Hexcel Corporation unveiled advancements in lightweight composite technologies aimed at the aerospace sector, while Solvay announced a collaboration with major automotive manufacturers to enhance production efficiencies. PolyOne Corporation has also focused on strategic partnerships to scale innovations in specialty compounds. 

Notably, DuPont and Eastman Chemical Company are exploring new applications of thermoplastic composites in the electrical and electronics industries, a trend gaining traction. Mergers and acquisitions are also prominent; in August 2023, LANXESS completed the acquisition of a thermoplastic composite division from A. Schulman to bolster its portfolio. 

Similarly, Teijin Limited in July 2023 announced its intention to acquire a minority stake in Toray Industries to enhance collaboration around advanced composite materials. The strong market valuation growth among these players is indicative of the rising demand and applications of thermoplastic composites across various sectors, positioning the US as a leader in this innovation-driven market.

    • US Thermoplastic Composites Market Segmentation Insights
    • Thermoplastic Composites Market Resin Type Outlook
      • Polyamide
    • Polypropylene
    • PEEK
    • Hybrid
    • Others
    • Thermoplastic Composites Market Fiber Type Outlook
      • Glass Fiber
    • Carbon Fiber
    • Others
    • Thermoplastic Composites Market Product Type Outlook
      • SFT
    • LFT
    • CFT
    • GMT

    • Thermoplastic Composites Market Application Outlook

      • Aerospace Défense

    • Automotive Transportation

    • Consumer Goods

    • Others

Future Outlook

US Thermoplastic Composites Market Future Outlook

The US thermoplastic composites market is projected to grow at 8.31% CAGR from 2024 to 2035, driven by advancements in manufacturing processes and increasing demand in automotive and aerospace sectors.

New opportunities lie in:

  • Development of lightweight thermoplastic composite structures for electric vehicles.
  • Investment in automated production technologies to enhance efficiency.
  • Expansion into renewable energy applications, such as wind turbine blades.

By 2035, the thermoplastic composites market is expected to achieve substantial growth and innovation.

Market Segmentation

US Thermoplastic Composites Market End Use Outlook

  • Structural Components
  • Interior Components
  • Exterior Components
  • Electrical Components

US Thermoplastic Composites Market Application Outlook

  • Aerospace
  • Automotive
  • Consumer Goods
  • Electronics
  • Industrial

US Thermoplastic Composites Market Material Type Outlook

  • Polypropylene
  • Polyamide
  • Polycarbonate
  • Polyethylene

US Thermoplastic Composites Market Reinforcement Type Outlook

  • Glass Fiber
  • Carbon Fiber
  • Natural Fiber
  • Aramid Fiber

US Thermoplastic Composites Market Manufacturing Process Outlook

  • Injection Molding
  • Compression Molding
  • Thermoforming
  • Filament Winding

Report Scope

MARKET SIZE 20244.69(USD Million)
MARKET SIZE 20255.08(USD Million)
MARKET SIZE 203511.3(USD Million)
COMPOUND ANNUAL GROWTH RATE (CAGR)8.31% (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 ProfiledToray Industries (JP), BASF (DE), SABIC (SA), Solvay (BE), Mitsubishi Chemical (JP), Teijin Limited (JP), Hexcel Corporation (US), Celanese Corporation (US), DuPont (US)
Segments CoveredApplication, End Use, Material Type, Manufacturing Process, Reinforcement Type
Key Market OpportunitiesGrowing demand for lightweight materials in automotive and aerospace sectors drives US thermoplastic composites market expansion.
Key Market DynamicsRising demand for lightweight materials drives innovation and competition in the US thermoplastic composites market.
Countries CoveredUS

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FAQs

What was the market size of the US Thermoplastic Composites Market in 2024?

The US Thermoplastic Composites Market was valued at 6259.72 USD Million in 2024.

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

By 2035, the market is expected to reach a value of 15834.01 USD Million.

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

The market is expected to grow at a compound annual growth rate of 8.803% from 2025 to 2035.

What are the key resin types in the US Thermoplastic Composites Market?

Key resin types include Polyamide, Polypropylene, PEEK, Hybrid, and Others.

How large is the Polyamide segment of the US Thermoplastic Composites Market in 2024?

The Polyamide segment is valued at 1750.0 USD Million in 2024.

What will be the market size for Polypropylene in 2035?

The Polypropylene segment is projected to be valued at 3800.0 USD Million by 2035.

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

Major players include SABIC, Mitsubishi Chemical Corporation, and Hexcel Corporation, among others.

What was the market size for the PEEK segment in 2024?

The PEEK segment was valued at 1200.0 USD Million in 2024.

What are the growth opportunities in the US Thermoplastic Composites Market?

Key growth opportunities are driven by increasing demand in automotive, aerospace, and consumer goods applications.

What is the projected market size for the Hybrid segment in 2035?

The Hybrid segment is expected to reach a value of 3000.0 USD Million by 2035.

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

The US Thermoplastic Composites Market is expected to be valued at 6300.0 USD Million in 2024.

What is the projected market size for the US Thermoplastic Composites Market in 2035?

In 2035, the US Thermoplastic Composites Market is projected to reach a value of 15700.0 USD Million.

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

The expected CAGR for the US Thermoplastic Composites Market is 8.655% from 2025 to 2035.

Which resin type is projected to have the largest market share in 2035?

By 2035, Polyamide is projected to have the largest market share, valued at 3160.0 USD Million.

What are the expected market values for Polypropylene in 2024 and 2035?

Polypropylene is expected to be valued at 1440.0 USD Million in 2024 and 3560.0 USD Million in 2035.

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

Key players in the market include BASF, Park Aerospace, Northrop Grumman, and DuPont among others.

What is the market size for PEEK resin in the US Thermoplastic Composites Market for 2024?

The market size for PEEK resin is expected to be 960.0 USD Million in 2024.

What are the market projections for Hybrid resin from 2024 to 2035?

Hybrid resin is projected to grow from 720.0 USD Million in 2024 to 1800.0 USD Million in 2035.

What impact do emerging trends have on the US Thermoplastic Composites Market?

Emerging trends are driving innovation and increasing the adoption of thermoplastic composites across various applications.

What are the market projections for the Others resin type from 2024 to 2035?

The Others resin type is anticipated to grow from 1920.0 USD Million in 2024 to 4840.0 USD Million in 2035.

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