Aerostructures Market – Global Industry Size, Share, Trends, Opportunity, and Forecast, Segmented By Component (Fuselage, Flight Control Surfaces, Wings, Nose, Nacelle and Pylon, and Others), By Material (Composite, Alloys, and Metals), By End-Use (OEM and Aftermarket), By Platform (Fixed Wing and Rotary Wing), By Region, Competition, 2021-2031F

Forecast Period	2027-2031
Market Size (2025)	USD 79.34 Billion
CAGR (2026-2031)	6.92%
Fastest Growing Segment	Wing
Largest Market	North America
Market Size (2031)	USD 118.53 Billion

Market Overview

The Global Aerostructures Market will grow from USD 79.34 Billion in 2025 to USD 118.53 Billion by 2031 at a 6.92% CAGR. Aerostructures consist of the critical load-bearing components of an airframe, including the fuselage, wings, empennage, and nacelles, which are engineered from advanced metallic and composite alloys to ensure aerodynamic performance and structural integrity. The market is primarily driven by the imperative for airlines to modernize fleets with fuel-efficient aircraft and a sustained surge in global air travel demand that necessitates higher production rates. This strong upward momentum is evidenced by recent traffic data. According to the International Air Transport Association, in 2024, total global revenue passenger kilometers increased by 10.4% compared to the previous year, underscoring the acute need for additional capacity.

However, the sector faces a significant impediment regarding supply chain fragility which could hamper anticipated growth. Persistent bottlenecks in procuring aerospace-grade raw materials and a shortage of skilled manufacturing labor have created production delays and extended lead times for original equipment manufacturers. These logistical constraints restrict the ability of suppliers to fully meet the escalating order backlogs, thereby serving as a major challenge to the rapid expansion of the global aerostructures market.

Key Market Drivers

Accelerated commercial aircraft fleet replacement programs are fundamentally reshaping the demand curve for fuselage sections, wings, and empennages. Airlines are aggressively retiring older models to adopt modern platforms that utilize lighter materials to reduce operating costs and meet sustainability goals. This transition compels original equipment manufacturers to increase monthly production rates, directly intensifying the requirement for sub-assemblies and airframe components. According to Boeing, July 2024, in the 'Commercial Market Outlook 2024-2043', the aviation industry will require 43,975 new commercial airplanes over the next two decades to meet replacement and growth needs. This long-term forecast provides structural suppliers with the necessary visibility to invest in capacity expansion and automation.

Escalating defense budgets and military fleet modernization simultaneously provide a robust revenue stream for aerostructure specialists distinct from commercial cycles. Rising geopolitical tensions have prompted governments to prioritize the acquisition of next-generation fighter jets and transport aircraft, which necessitate specialized composite and metallic structures for enhanced durability. According to the Stockholm International Peace Research Institute, April 2024, in the 'Trends in World Military Expenditure, 2023' Fact Sheet, total global military expenditure rose by 6.8% in real terms to reach $2443 billion. To support this dual-front demand from both civil and defense sectors, major integrators are maintaining historically high order books. According to Airbus, in 2024, the company held an order backlog amounting to 8,749 commercial aircraft as of September 30, reflecting the sustained pressure on the supply chain to deliver critical airframe hardware.

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Key Market Challenges

Supply chain fragility and the persistent shortage of skilled labor constitute a formidable barrier to the expansion of the Global Aerostructures Market. Although airlines are aggressively seeking to update fleets, manufacturers are physically restricted by their inability to consistently source essential aerospace-grade raw materials and qualified technical personnel. This operational bottleneck disrupts the complex assembly rhythm required for critical components such as fuselages and wings, causing significant deviations from production schedules. Consequently, the market is experiencing a decoupling of demand from supply, where revenue recognition is delayed because finished aerostructures cannot be delivered at the pace required by original equipment manufacturers.

The magnitude of this constraint is clearly illustrated by the growing disparity between confirmed orders and actual manufacturing output. According to the International Air Transport Association, in 2024, the global commercial aircraft backlog reached a historic high of more than 17,000 units. This substantial accumulation of unfilled orders indicates that despite robust market interest, the sector lacks the immediate industrial capacity to convert demand into tangible growth. These logistical and labor-related impediments effectively cap the market’s performance, preventing suppliers from fully capitalizing on the sustained recovery in global air travel.

Key Market Trends

The Expansion of Automated Fiber Placement and Robotic Assembly is becoming critical as manufacturers seek to stabilize production rates and mitigate skilled labor shortages. Suppliers are increasingly transitioning from manual lay-up processes to high-speed automated systems that ensure consistent quality for complex composite sections. This shift decouples manufacturing capacity from workforce constraints, enabling predictable output for fuselage and wing assemblies. The scale of this technological pivot is evident in recent capital expenditures; according to AMT – The Association For Manufacturing Technology, August 2025, in the 'Machinery Orders Rise as Automation Grows, Aerospace Soars' report, the aerospace sector increased the value of manufacturing technology orders by 6% in the first half of 2025 compared to the previous year. This investment surge confirms a broad industrial commitment to robotic integration.

Simultaneously, the Industrialization of Additive Manufacturing for Structural Components is advancing into full-scale production to address supply chain volatility. Manufacturers are utilizing this technology to produce lightweight parts with reduced material waste, consolidating multi-part sub-assemblies into monolithic structures. This approach streamlines the supply chain by enabling the on-demand fabrication of critical hardware, thereby reducing dependency on casting and forging lead times. Validating this trajectory, according to GKN Aerospace, December 2025, in the 'GKN Aerospace to Expand Additive Manufacturing capabilities in Norway' press release, the company announced a co-investment of NOK 12 million to industrialize additive manufacturing processes. Such initiatives highlight the sector's strategic move towards digital inventory to enhance manufacturing resilience.

Segmental Insights

Recent market analysis identifies the Wing segment as the fastest-growing category within the Global Aerostructures Market. This rapid expansion is primarily driven by the aviation industry's strategic shift toward lightweight composite materials, such as carbon fiber, which are replacing heavy metallic alloys to optimize structural efficiency. As airlines face increasing pressure from institutions like the International Civil Aviation Organization (ICAO) to lower carbon emissions, the demand for aerodynamically superior designs that minimize fuel burn has surged. Consequently, manufacturers are prioritizing the production of these advanced wing structures to support extensive fleet modernization programs globally.

Regional Insights

North America holds a leading position in the global aerostructures market, driven by the strong presence of major aircraft manufacturers and a mature supply chain network. The United States contributes significantly through high defense spending and consistent demand for commercial aircraft, which supports continuous production activities. Additionally, the Federal Aviation Administration plays a critical role in establishing rigorous safety protocols that necessitate the adoption of reliable manufacturing technologies. The widespread integration of composite materials and automated assembly processes further strengthens the regional industrial base, ensuring North America remains a central hub for aerospace development.

Recent Developments

• In April 2025, Airbus SE entered into a definitive agreement to acquire substantial industrial assets from Spirit AeroSystems, aiming to ensure the stability of supply for its commercial aircraft programs. The transaction included the acquisition of production facilities in Kinston, North Carolina, and St. Nazaire, France, which are responsible for A350 fuselage sections, as well as A220 manufacturing sites in Belfast, Northern Ireland, and Casablanca, Morocco. As part of the deal, the European manufacturer agreed to receive $439 million in compensation from Spirit AeroSystems, marking a major consolidation effort to vertically integrate critical aerostructure work packages.
• In January 2025, Daher strengthened its industrial footprint in North America by signing a long-term lease for its aerostructures assembly facility in Stuart, Florida. This strategic move was designed to secure the company's production capabilities for critical components, including horizontal stabilizers for the Boeing 767 freighter and the KC-46 aerial tanker. By solidifying its presence at this site, the company aimed to increase its assembly capacity and workforce to meet growing demand from major U.S. aerospace customers, further cementing its role as a key Tier 1 supplier in the global market.
• In July 2024, GKN Aerospace announced a strategic technology collaboration with the German aircraft manufacturer Vaeridion to advance the development of aerostructures and electrical wiring interconnection systems for electric aviation. Signed at the Farnborough Airshow, this partnership focused on optimizing the airframe design and electrical systems for Vaeridion’s planned nine-passenger all-electric microliner. Under the agreement, GKN Aerospace committed to leveraging its expertise in lightweight composite structures and wiring systems to support the aircraft's certification and industrialization, marking a significant step forward in the company's engagement with sustainable, next-generation flight technologies.
• In February 2024, Spirit AeroSystems officially opened a new engineering design center in Subang, Malaysia, to enhance its global engineering capabilities and support increasing customer demand. Located within the company's existing manufacturing plant, this facility was established to provide around-the-clock engineering services for the company’s global operations, including design work for the Airbus A350 freighter and A220 wing programs. The Senior Vice President of Spirit AeroSystems stated that the center would improve engineering turnaround times and leverage the region's skilled workforce, further solidifying the company's position in the global aerostructures supply chain.

Key Market Players

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

By Component	By Material	By End-Use	By Platform	By Region
Fuselage Flight Control Surfaces Wings Nose Nacelle and Pylon Others	Composite Alloys Metals	OEM and Aftermarket	Fixed Wing and Rotary Wing	North America Europe Asia Pacific South America Middle East & Africa

Report Scope:

In this report, the Global Aerostructures Market has been segmented into the following categories, in addition to the industry trends which have also been detailed below:

• 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 and Aftermarket

• Aerostructures Market, By Platform:

• Fixed Wing and Rotary Wing

• Aerostructures Market, By Region:

• North America
• United States
• Canada
• Mexico
• Europe
• France
• United Kingdom
• Italy
• Germany
• Spain
• Asia Pacific
• China
• India
• Japan
• Australia
• South Korea
• South America
• Brazil
• Argentina
• Colombia
• Middle East & Africa
• South Africa
• Saudi Arabia
• UAE