Aerospace Foams Global Market Report 2024

Aerospace foams, characterized by their cellular structure and low-density composition, play a pivotal role in diverse aircraft components. Their exceptional attributes, including high tensile strength, durability, rigidity, and lightweight nature, make them integral for applications aimed at reducing fuel consumption and, consequently, lowering overall infrastructure expenses in the aviation sector.

The primary variants of aerospace foams include polyurethane, polyimide, metal foams, melamine, polyethylene, and other specialized formulations. Polyurethane, a synthetic polymer featuring urethane radicals, finds predominant use in various applications such as vibration damping, cushioning, insulation, and packaging. Its applications span across aircraft components like seats, floor carpets, cabin walls, ceilings, flight deck pads, and overhead stow bins. These versatile applications cater to end-users in the general aviation, commercial aviation, and military aircraft sectors.

The aerospace foams market research report is one of a series of new reports that provides aerospace foams market statistics, including aerospace foams industry global market size, regional shares, competitors with the aerospace foams market share, detailed aerospace foams market segments, market trends and opportunities, and any further data you may need to thrive in the aerospace foams industry. This aerospace foams market research report delivers a complete perspective of everything you need, with an in-depth analysis of the current and future scenario of the industry.

The aerospace foams market size has grown strongly in recent years. It will grow from $5.11 billion in 2023 to $5.51 billion in 2024 at a compound annual growth rate (CAGR) of 7.8%. The growth observed in the historic period can be attributed to several factors, including an increase in defense budgets, expansion of the aerospace industry, modernization of aircraft fleets, and the implementation of stringent safety regulations. These combined influences have contributed to a positive trajectory in the aerospace sector during that timeframe.

The aerospace foams market size is expected to see strong growth in the next few years. It will grow to $7.42 billion in 2028 at a compound annual growth rate (CAGR) of 7.7%. The anticipated growth in the forecast period is driven by various factors, including the increasing popularity of urban air mobility, a surge in space tourism, a heightened demand for enhanced aircraft interior comfort, a rise in air traffic, and an overall increase in disposable income. Additionally, noteworthy trends expected in this period encompass the adoption of sustainable materials, the integration of 3D printing technology, advancements in insulation techniques, the use of noise reduction materials, and the implementation of fire-resistant foams. These trends reflect the ongoing efforts to innovate and enhance the overall performance, safety, and sustainability of aerospace materials and technologies.

The expansion of the commercial aircraft fleet size significantly drives the growth of the aerospace foams market. The aircraft fleet represents the total number of airplanes in operation by airlines. The growing fleet size necessitates the incorporation of aerospace foams into aircraft designs, utilized in various components such as seats, cabin walls, ceilings, floor carpets, flight deck pads, and overhead stow bins. This escalating need for aerospace foams, as highlighted in Boeing's commercial market outlook for 2021–2040, forecasts a global commercial fleet exceeding 49,000 airplanes by 2040. Hence, the escalating fleet size of commercial aircraft stands as a pivotal driver in advancing the aerospace foams market.

The increasing count of air passengers worldwide is poised to further propel the aerospace foams market. Air passengers constitute individuals traveling via commercial airlines or private aircraft. This surge in air travel necessitates enhanced passenger comfort, fuel efficiency, noise reduction, safety measures, and compliance with regulations, thus driving the demand for aerospace foams. For example, based on the World Air Transport Statistics (WATS) database in 2021, which collates information from over 250 international airlines, the total number of passengers carried on scheduled services surged to 2.3 billion, marking a 28.1% increase compared to 2020. This burgeoning air passenger count substantiates the increased demand for aerospace foams globally.

Product innovations are shaping the landscape of the aerospace foams market, as major industry players are introducing innovative foam products for aircraft applications. These foams find utility in various parts of aircraft designs such as seats, cabin walls, ceilings, and more. Notably, in November 2021, SINOYQX, a China-based melamine foam manufacturer, unveiled the YQX Bonded foam. This composite foam, integrating rebounded elements, boasts vibration-damping, acoustic insulating, and fire-resistance properties. It contributes to sustainable development by reducing waste from melamine and PU foam, employing shredded flexible melamine foam or recycled PU foam. The product offers enhanced strength and durability compared to pure melamine foam, representing a significant innovation in the aerospace foams sector.

Major players in the aerospace foams market are strategically prioritizing production capacity expansion. This involves making investments to increase their production capabilities, address rising demand, and enhance operational efficiency. In April 2022, Evonik Industries AG, a German specialty chemicals company, made a significant investment in a state-of-the-art production facility for its high-performance foams designed for fiber composite cores. This facility is located in Darmstadt, Germany. The new production plant specializes in the manufacturing of high-performance polymethacrylimide (PMI) foam, which serves as a core material in sandwich composite materials. The expansion of this production facility equips Evonik to meet the increasing demand for its structural foams, particularly in the aerospace sector, as well as other industries.

In May 2021, Diab, a Swedish company specializing in foam core materials and sandwich technology, acquired the ULTEM foam production line from SABIC, a Saudi Arabia-based company. While the financial details of the transaction remain undisclosed, this acquisition is expected to diversify Diab's product portfolio and strengthen its market position in offering core materials. SABIC, as a provider of foams for aerospace interior applications, has contributed to enhancing Diab's capabilities and offerings within the aerospace foams market.

Major companies operating in the aerospace foams market include Badische Anilin- und Sodafabrik, Evonik Industries AG, Boyd Corporation, Rogers Corporation, FoamPartner Group, Armacell International SA, Saudi Basic Industries Corporation, ERG Materials and Aerospace Corp, UFP Technologies Inc., Zotefoams PLC, General Plastics Manufacturing Co, Solvay SA, Greiner AG, Pyrotek Inc., Technifab Inc., Reiner Aerospace Inc., 3A Composites India Pvt Ltd., Aerofoam Industries LLC, Diab Group, DuPont de Nemours Inc., Grand Rapids Foam Technologies, Recticel NV/SA, Huntsman Corporation, NCFI Polyurethanes, Neill Corporation, Sekisui Aerospace Corporation, FXI Holdings Inc., Covestro AG, BASF SE, Azelis Holding SA, Reichhold Holdings US Inc.

North America was the largest region in the aerospace foams market in 2023. Asia-Pacific is expected to be the fastest-growing region in the aerospace foams market share during the forecast period. The regions covered in the aerospace foams market analysis report are Asia-Pacific, Western Europe, Eastern Europe, North America, South America, Middle East and Africa.

The countries covered in the aerospace foams market report are Australia, Brazil, China, France, Germany, India, Indonesia, Japan, Russia, South Korea, UK, USA.

The aerospace foams market consists of sales of ceramic foam, natural rubber, silicone rubber, ethylene-propylene diene monomer, and styrene butadiene rubber. Values in this market are ‘factory gate’ values, that is the value of goods sold by the manufacturers or creators of the goods, whether to other entities (including downstream manufacturers, wholesalers, distributors and retailers) or directly to end customers. The value of goods in this market includes related services sold by the creators of the goods.

The market value is defined as the revenues that enterprises gain from the sale of goods and/or services within the specified market and geography through sales, grants, or donations in terms of the currency (in USD unless otherwise specified).

The revenues for a specified geography are consumption values that are revenues generated by organizations in the specified geography within the market, irrespective of where they are produced. It does not include revenues from resales along the supply chain, either further along the supply chain or as part of other products.


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