Aircraft Engine Casting Market – Global Industry Size, Share, Trends, Opportunity, and Forecast, Segmented By Aircraft Type (Commercial Aircraft, Regional Aircraft, Helicopter, Military Aircraft, and General Aviation), By Engine Type (Turbofan, Turboprop, Turbojet, and Turboshaft), By Material Type (Nickel, Titanium, Stainless Steel, and Others), By Region & Competition, 2020-2030F

Market Overview

The Global Aircraft Engine Casting Market, valued at USD 12.80 Billion in 2024, is projected to experience a CAGR of 6.76% to reach USD 18.95 Billion by 2030. Aircraft engine castings are highly engineered metal components produced through precision casting processes, essential for the performance, durability, and structural integrity of aero-engines. The market growth is primarily driven by the escalating global demand for air travel, leading to increased aircraft production and a rise in maintenance, repair, and overhaul activities. Additionally, consistent defense spending globally supports the demand for military aircraft engine components. According to the Aerospace Industries Association (AIA), the U. S. aerospace and defense industry generated over $955 billion in sales in 2023, a 7.1 percent increase from the previous year, underscoring the robust demand for core aerospace products.

A significant challenge impeding market expansion is the complex and protracted qualification processes for new materials and advanced manufacturing techniques. These rigorous regulatory requirements often extend development timelines and increase costs, posing a barrier to rapid innovation and market entry for new solutions within the aircraft engine casting sector.

Key Market Drivers

Increasing aircraft production and fleet expansion significantly influences the Global Aircraft Engine Casting Market across both commercial and military aviation sectors. As airlines modernize their fleets and global air travel demand rises, the manufacturing of new aircraft, each requiring multiple engines, directly elevates the need for high-integrity engine castings. According to Airbus, in January 2024, the company aimed to deliver approximately 800 commercial aircraft in 2024, signaling robust production levels that translate into substantial demand for engine components. Concurrently, a pronounced industry focus on fuel efficiency and advanced engine performance serves as another critical driver. Engine manufacturers continuously invest in research and development to create more efficient and powerful engines, which often necessitate complex, high-performance castings capable of withstanding extreme operational conditions. This imperative drives the adoption of innovative casting techniques and advanced material alloys. According to GE Aerospace, in July 2024, CFM International received orders and commitments for more than 4,500 LEAP engines in 2023, underscoring the ongoing industry shift towards superior fuel efficiency.

These converging drivers necessitate continuous advancements in casting technology and material science to meet stringent performance and safety standards. The sustained growth in aerospace manufacturing globally, driven by these factors, directly correlates with demand for high-quality engine castings. According to the Aerospace Industries Association, in February 2024, U. S. aerospace and defense industry sales are projected to reach nearly $1.1 trillion in 2024, highlighting the substantial economic activity underpinning the component supply chain, including engine castings.

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Key Market Challenges

The complex and protracted qualification processes for new materials and advanced manufacturing techniques represent a significant impediment to the growth of the Global Aircraft Engine Casting Market. These rigorous regulatory requirements for aircraft engine components necessitate extensive testing and validation, which in turn extends development timelines and significantly increases associated costs. This directly delays the introduction of innovative casting solutions into the market.

Such prolonged approval cycles slow down the integration of advanced casting technologies and high-performance alloys designed to enhance engine efficiency and durability. The resultant delays impact the broader aerospace supply chain. According to the Aerospace Industries Association, in 2023, the sector experienced an average delay of 8.5 weeks in the delivery of critical components. This increase in lead times for specialized castings hinders the timely production of new aircraft and delays maintenance, repair, and overhaul activities, thereby restricting overall market expansion and the adoption of next-generation engine designs.

Key Market Trends

Additive Manufacturing Integration in Production represents a pivotal trend in the Global Aircraft Engine Casting Market by enabling the creation of complex, lightweight components with optimized designs that are unachievable through traditional casting methods. This technology facilitates the consolidation of multiple parts into single units, reducing assembly complexity and overall engine weight, which directly contributes to enhanced fuel efficiency. The increasing demand for air travel continues to drive this adoption, with the International Air Transport Association reporting that total passenger traffic for 2023 rose by 36.9% compared to 2022, reaching 94.1% of pre-pandemic levels. A joint survey conducted by the Royal Aeronautical Society and Protolabs in June 2024 highlighted additive manufacturing as the preferred technology for prototyping and manufacturing in the aerospace sector, chosen by 74.09% of respondents, indicating its increasing mainstream integration beyond just rapid prototyping.

Sustainability in Materials and Manufacturing Processes is another significant trend transforming the market, driven by growing environmental concerns and regulatory pressures. This involves the development and application of sustainable alloys, the reduction of material waste, and the implementation of energy-efficient production techniques within casting operations. The International Aerospace Environmental Group (IAEG), whose member companies represent 70% of the global aerospace and defense industry, continued in 2024 to expand its scope to address crucial areas like the circular economy and sustainable aviation fuels, demonstrating a collective industry commitment. Boeing's 2024 Sustainability Report, released in June 2024, stated that the company achieved 39% renewable electricity in 2023 and established a plan for all production commercial airplanes to be 100% Sustainable Aviation Fuel compatible by 2030, underscoring the imperative for greener manufacturing and material integration across the sector.

Segmental Insights

The Global Aircraft Engine Casting Market observes Turbofan Engines as the fastest-growing segment. This growth is primarily fueled by the increasing global demand for new commercial aircraft and business jets, driven by rising air passenger traffic and fleet modernization initiatives. Airlines prioritize turbofan engines for their superior fuel efficiency and reduced emissions, a critical factor in meeting environmental standards set by organizations such as the International Civil Aviation Organization (ICAO). Consequently, there is sustained demand for advanced, high-performance cast components, utilizing sophisticated materials and precision casting techniques to achieve lighter, more durable, and efficient engine designs.

Regional Insights

North America leads the global aircraft engine casting market, primarily driven by its established position as a prominent aerospace manufacturing hub. The region benefits from the strong presence of major aircraft original equipment manufacturers, such as Boeing, and engine giants like GE Aerospace and Pratt & Whitney, which are significant consumers of cast components. This dominance is further supported by a robust infrastructure, continuous investment in advanced technology, and a highly skilled workforce. The stringent regulatory environment, exemplified by oversight from bodies such as the Federal Aviation Administration, ensures the high quality and reliability demanded for critical aircraft engine parts, solidifying North America's market leadership.

Recent Developments

• In October 2025, researchers at MIT developed a printable aluminum alloy with properties five times stronger than traditionally manufactured aluminum, designed for high-temperature applications. This breakthrough facilitated the potential for lighter, more temperature-resistant components such as fan blades in jet engines. The new material presented a more cost-effective and lighter alternative to titanium or advanced composites commonly used for cast components. Its additive manufacturing process also offered quicker cooling compared to conventional metal casting, signaling a shift in manufacturing approaches for crucial aircraft engine parts aimed at enhancing energy efficiency in transportation.

• In October 2025, Safran Aircraft Engines integrated three CeraFab S65 ceramic 3D printers from Lithoz at its facility in Gennevilliers. These machines were dedicated to manufacturing advanced ceramic casting cores essential for turbine blades in next-generation aircraft engines. This strategic collaboration aimed to create intricate internal cooling channels, enabling turbine blades to endure extreme temperatures and significantly improve engine efficiency. The companies refined the Lithography-based Ceramic Manufacturing (LCM) process to ensure scalable production for aerospace applications. This initiative marked a notable step towards large-scale ceramic additive manufacturing to support future propulsion system development within the aircraft engine casting sector.

• In June 2024, a NASA engineer developed an innovative 3D-printable alloy capable of withstanding extreme conditions, including temperatures over 2000 degrees Fahrenheit. This breakthrough material enabled the creation of lighter, thinner, and stronger parts for jet and rocket engines. Its superior durability and heat resistance represented a significant advancement for the aerospace industry, addressing critical challenges in engine design. Four companies subsequently licensed this new technology, highlighting substantial commercial interest and its potential to influence manufacturing processes for high-performance aircraft engine components, offering an alternative to traditional casting methods for such demanding applications.

• In early 2024, Safran Aircraft Engines and PTC Industries formalized a multi-year contract for industrial cooperation, specifically focusing on the production of titanium casting parts. Under this agreement, PTC Industries began manufacturing titanium components for Safran’s LEAP engines, with initial deliveries of these critical parts commencing that year for engines powering single-aisle jets. This collaboration aimed to bolster Safran's global supply chain for LEAP engine production, contributing to enhanced engine manufacturing capabilities. PTC Industries applied its expertise in advanced casting processes to meet the stringent requirements for high-quality aircraft engine components in the global market.

Key Market Players

• Precision Castparts
• Howmet Aerospace
• Arconic
• Consolidated Precision Products
• MetalTek
• Impro
• Zollern
• Milwaukee Precision
• Casting Technology
• Hitchiner

Report Scope:

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

• Aircraft Engine Casting Market, By Aircraft Type:

o   Commercial Aircraft

o   Regional Aircraft

o   Helicopter

o   Military Aircraft

o   General Aviation

• Aircraft Engine Casting Market, By Engine Type:

o   Turbofan

o   Turboprop

o   Turbojet

o   Turboshaft

• Aircraft Engine Casting Market, By Material Type:

o   Nickel

o   Titanium

o   Stainless Steel

o   Others

• Aircraft Engine Casting Market, By Region:

o   North America

§  United States

§  Canada

§  Mexico

o   Europe

§  France

§  United Kingdom

§  Italy

§  Germany

§  Spain

o   Asia Pacific

§  China

§  India

§  Japan

§  Australia

§  South Korea

o   South America

§  Brazil

§  Argentina

§  Colombia

o   Middle East & Africa

§  South Africa

§  Saudi Arabia

§  UAE

Competitive Landscape

Company Profiles: Detailed analysis of the major companies presents in the Global Aircraft Engine Casting Market.

Available Customizations:

Global Aircraft Engine Casting Market report with the given market data, TechSci Research offers customizations according to a company's specific needs. The following customization options are available for the report:

Company Information

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

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