Rapid Prototyping in Aerospace and Defense Market Report 2025

The rapid prototyping in aerospace and defense market size has grown rapidly in recent years. It will grow from $2.07 billion in 2024 to $2.28 billion in 2025 at a compound annual growth rate (CAGR) of 10%. The growth during the historic period can be attributed to the increasing adoption of 3D printing for prototype validation, rising demand for lightweight defense components, greater reliance on computer-aided design (CAD) in aerospace design, enhanced collaboration for prototype testing, and expanded use of computer numerical control (CNC) machining in part fabrication.

The rapid prototyping in aerospace and defense market size is expected to see strong growth in the next few years. It will grow to $3.31 billion in 2029 at a compound annual growth rate (CAGR) of 9.8%. The growth anticipated in the forecast period is driven by increasing investment in hypersonic and space programs, expanded use of rapid prototyping for unmanned systems, a growing need for faster product development cycles, broader adoption of additive manufacturing within defense supply chains, and rising demand for customized aircraft components. Key trends during this period include advancements in metal additive manufacturing, innovations in hybrid prototyping methods, increased research and development funding, progress in high-performance aerospace materials, and automation of prototyping workflows.

The increasing demand for aircraft is expected to drive the growth of the rapid prototyping market for aerospace and defense in the coming years. An aircraft includes any flying machine or vehicle such as airplanes, helicopters, or drones. This demand is growing due to the rise in air travel, with more people opting for flights for business and tourism purposes. Lower ticket prices and improved airport infrastructure have made flying more accessible, encouraging airlines to expand their fleets. Aircraft manufacturers utilize rapid prototyping to quickly design, test, and refine aerospace and defense components, which helps reduce development time and costs. For example, in May 2025, Airbus SE, a France-based commercial aircraft manufacturer, reported that commercial aircraft deliveries increased by 4% in 2024 compared to 2023, with 766 aircraft delivered, up from 735 the previous year. Additionally, total commercial aircraft orders reached 2,094 in 2024, a notable rise from 820 orders in 2023. Thus, the rising demand for aircraft is fueling growth in the rapid prototyping market for aerospace and defense.

Key companies in the rapid prototyping market for aerospace and defense are focusing on technological innovations such as portable directed energy deposition (DED) systems to enable on-demand metal manufacturing and repairs in the field. Portable DED systems use laser or electron energy to fuse metal wire or powder directly onto surfaces, allowing for precise component production or repairs in remote locations. For instance, in February 2025, ADDiTEC Technologies Ltd., a US-based industrial 3D printing company, launched the AMDROiD X. This system features a self-contained modular container with integrated solar-rechargeable batteries, multi-axis robotic motion control, and an optional 12 kW fiber laser that enables metal deposition at rates up to 4 kg per hour for rapid manufacturing and repair of aerospace and defense parts in austere environments. It improves deployment readiness by providing autonomous metal 3D printing capabilities directly at forward operating bases or critical mission sites.

In April 2025, Nano Dimension Ltd., a US-based machinery industry company, acquired Markforged for an undisclosed amount. This acquisition strengthens Nano Dimension’s intelligent digital manufacturing capabilities by combining its precision additive manufacturing expertise with Markforged’s AI-driven software and industrial 3D printing technologies. Markforged, based in the US, specializes in rapid prototyping and the production of durable parts for aerospace and defense applications.

Major players in the rapid prototyping in aerospace and defense market are The Boeing Company, Lockheed Martin Corporation, Airbus SE, Northrop Grumman Corporation, GE Aerospace, Renishaw plc, Stratasys Ltd., 3D Systems Corporation, Proto Labs Inc., Materialise NV, Nikon SLM Solutions Group AG, ExOne Company, Ultimaker BV, Hoganas AB, Nano Dimension Ltd., VoxelJet AG, EOS GmbH, AON3D Inc., Sciaky Inc., and CRP Technology S.r.l.

North America was the largest region in the rapid prototyping in aerospace and defense market in 2024. Asia-Pacific is expected to be the fastest-growing region in the forecast period. The regions covered in rapid prototyping in aerospace and defense report are Asia-Pacific, Western Europe, Eastern Europe, North America, South America, Middle East and Africa. The countries covered in the rapid prototyping in aerospace and defense market report are Australia, Brazil, China, France, Germany, India, Indonesia, Japan, Russia, South Korea, UK, USA, Canada, Italy, Spain.

Note that the outlook for this market is being affected by rapid changes in trade relations and tariffs globally. The report will be updated prior to delivery to reflect the latest status, including revised forecasts and quantified impact analysis. The report’s Recommendations and Conclusions sections will be updated to give strategies for entities dealing with the fast-moving international environment.

The sharp hike in U.S. tariffs and the associated trade disputes in spring 2025 are notably impacting the aerospace and defense sector by raising costs for titanium, carbon fiber composites, and avionics materials largely sourced from global suppliers. Defense contractors, locked into fixed-price government contracts, absorb these added costs, while commercial aerospace firms face airline pushback on higher aircraft prices. Delays in component shipments due to customs bottlenecks further disrupt tight production schedules for jets and satellites. The industry is responding by stockpiling critical materials, seeking waivers for defense-related imports, and collaborating with allied nations to diversify supply chain.

Rapid prototyping in aerospace and defense involves the fast production of physical parts or models using methods like 3D printing and additive manufacturing. This process allows engineers to design, test, and improve components more quickly than traditional manufacturing techniques. It helps shorten development timelines, reduce costs, and speed up innovation for aircraft, spacecraft, and defense systems.

The main rapid prototyping methods in aerospace and defense include stereolithography apparatus (SLA), laminated object manufacturing (LOM), selective laser sintering (SLS), three-dimensional printing (3DP), and fused deposition modeling (FDM). Stereolithography apparatus is a 3D printing method that uses a laser to solidify liquid resin layer by layer into solid parts. It enables the production of highly detailed prototypes with smooth surfaces and is commonly used for testing form and fit during early design stages. The technology encompasses 3D printing, computer-aided design (CAD), computer numerical control (CNC) machining, additive manufacturing, and hybrid manufacturing techniques. Applications span aircraft manufacturing, missile systems, spacecraft development, defense systems, and aerospace component production. End users include military organizations, civil aviation authorities, aerospace research institutions, private aerospace companies, and government defense contractors.

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

The rapid prototyping in aerospace and defense market consists of revenues earned by entities by providing services such as reverse engineering, digital twin simulation, rapid tooling customization, low-volume pre-production runs, and accelerated failure testing. The market value includes the value of related goods sold by the service provider or included within the service offering. The rapid prototyping in aerospace and defense market also includes sales of design validation models, wind tunnel scale prototypes, unmanned aerial vehicle structural parts, cockpit layout mockups, and thermal shielding test units. 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 and 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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