Aerostructures Market - Global Industry Size, Share, Trends, Opportunity, and Forecast, 2021-2031

The Global Aerostructures Market is projected to expand significantly, growing from USD 79.34 Billion in 2025 to USD 118.53 Billion by 2031, representing a CAGR of 6.92%. Aerostructures comprise essential load-bearing elements of an airframe, such as the fuselage, wings, empennage, and nacelles, which are manufactured using advanced metallic and composite alloys to guarantee structural integrity and aerodynamic performance. This growth is primarily fueled by the urgent need for airlines to upgrade fleets with fuel-efficient aircraft and a continuous rise in global air travel demand, necessitating increased production rates. This momentum is supported by recent traffic statistics; according to the International Air Transport Association, total global revenue passenger kilometers rose by 10.4% in 2024 compared to the prior year, highlighting the critical requirement for expanded capacity.

However, the industry faces a substantial hurdle regarding supply chain fragility, which threatens to impede the expected growth. Persistent difficulties in sourcing aerospace-grade raw materials and a scarcity of skilled manufacturing labor have led to production delays and prolonged lead times for original equipment manufacturers. These logistical constraints limit the ability of suppliers to effectively address mounting order backlogs, presenting a major challenge to the rapid expansion of the global aerostructures market.

Market Drivers

The aggressive implementation of commercial aircraft fleet replacement programs is fundamentally altering the demand landscape for fuselage sections, wings, and empennages. Airlines are actively retiring older models in favor of modern platforms that utilize lighter materials to cut operating costs and achieve sustainability targets, compelling original equipment manufacturers to increase monthly production rates and intensifying the need for sub-assemblies. According to Boeing’s "Commercial Market Outlook 2024-2043" released in July 2024, the aviation industry will require 43,975 new commercial airplanes over the next 20 years to satisfy replacement and growth needs, providing structural suppliers with the visibility necessary to invest in capacity expansion and automation.

Concurrently, rising defense budgets and military fleet modernization offer a strong revenue stream for aerostructure specialists, separate from commercial cycles. Escalating geopolitical tensions have led governments to prioritize next-generation fighter jets and transport aircraft, which require specialized composite and metallic structures for superior durability. According to the Stockholm International Peace Research Institute’s April 2024 Fact Sheet "Trends in World Military Expenditure, 2023," global military spending rose by 6.8% in real terms to reach $2.44 trillion. To support this dual demand from both civil and defense sectors, major integrators are maintaining substantial order books; for instance, Airbus reported a backlog of 8,749 commercial aircraft as of September 30, 2024, reflecting the intense pressure on the supply chain to deliver critical airframe hardware.

Market Challenges

Supply chain fragility and a persistent shortage of skilled labor represent a significant barrier to the expansion of the Global Aerostructures Market. While airlines are eager to modernize their fleets, manufacturers are physically constrained by an inability to consistently source essential aerospace-grade raw materials and qualified technical personnel. This operational bottleneck disrupts the intricate assembly rhythm required for critical components like fuselages and wings, resulting in notable deviations from production schedules. Consequently, the market is seeing a disconnect between supply and demand, where revenue recognition is delayed because finished aerostructures cannot be delivered at the pace requested by original equipment manufacturers.

The severity of this constraint is evident in the widening gap between confirmed orders and actual manufacturing output. According to the International Air Transport Association, the global commercial aircraft backlog hit a record high of over 17,000 units in 2024. This massive accumulation of unfilled orders demonstrates that, despite strong market interest, the sector lacks the immediate industrial capacity to convert demand into tangible growth. These logistical and labor-related impediments effectively limit the market’s performance, preventing suppliers from fully capitalizing on the sustained recovery in global air travel.

Market Trends

The adoption of Automated Fiber Placement and Robotic Assembly is becoming increasingly vital as manufacturers aim to stabilize production rates and mitigate skilled labor shortages. Suppliers are shifting from manual lay-up processes to high-speed automated systems that ensure consistent quality for complex composite sections, effectively decoupling manufacturing capacity from workforce constraints to allow for predictable output of fuselage and wing assemblies. The scale of this technological shift is reflected in capital expenditures; according to AMT - The Association For Manufacturing Technology’s August 2025 report "Machinery Orders Rise as Automation Grows, Aerospace Soars," the aerospace sector increased the value of manufacturing technology orders by 6% in the first half of 2025 compared to the previous year, confirming a strong industrial commitment to robotic integration.

Simultaneously, the industrialization of Additive Manufacturing for structural components is advancing toward full-scale production to address supply chain volatility. Manufacturers are leveraging this technology to create lightweight parts with minimal material waste, often consolidating multi-part sub-assemblies into monolithic structures. This approach streamlines the supply chain by enabling on-demand fabrication of critical hardware, thereby reducing reliance on casting and forging lead times. Validating this trend, GKN Aerospace announced in a December 2025 press release titled "GKN Aerospace to Expand Additive Manufacturing capabilities in Norway" a co-investment of NOK 12 million to industrialize additive manufacturing processes, highlighting the sector's strategic move toward digital inventory to enhance manufacturing resilience.

Key Players Profiled in the Aerostructures Market

• AAR Corp.
• Bombardier Inc.
• Ruag Group
• Saab AB
• Spirit Aerosystems, Inc.
• Stelia Aerospace Group
• Triumph Group, Inc.
• Cyient Ltd.
• Elbit Systems Ltd.
• GKN Aerospace

Report Scope

In this report, the Global Aerostructures Market has been segmented into the following categories:

Aerostructures Market, by Component:

• Fuselage
• Flight Control Surfaces
• Wings
• Nose
• Nacelle and Pylon
• Others

Aerostructures Market, by Material:

• Composite
• Alloys
• Metals

Aerostructures Market, by End-Use:

• OEM
• Aftermarket

Aerostructures Market, by Platform:

• Fixed Wing
• Rotary Wing

Aerostructures Market, by Region:

• North America
• Europe
• Asia-Pacific
• South America
• Middle East & Africa

Competitive Landscape

Company Profiles: Detailed analysis of the major companies present in the Global Aerostructures Market.

Available Customization

The analyst offers customization according to your specific needs. The following customization options are available for the report:

• Detailed analysis and profiling of additional market players (up to five).

This product will be delivered within 1-3 business days.