Aircraft Open Die Forging Market – Global Industry Size, Share, Trends, Opportunity, and Forecast, Segmented By Aircraft Type (Commercial Aircraft, Regional Aircraft, Helicopter, Military Aircraft, General Aviation), By Application Type (Airframe, Engine), By Component Size Type (Small Components, Large Components), By Region & Competition, 2021-2031F

Forecast Period	2027-2031
Market Size (2025)	USD 5.93 Billion
CAGR (2026-2031)	6.82%
Fastest Growing Segment	Large Components
Largest Market	North America
Market Size (2031)	USD 8.81 Billion

Market Overview

The Global Aircraft Open Die Forging Market will grow from USD 5.93 Billion in 2025 to USD 8.81 Billion by 2031 at a 6.82% CAGR. The Global Aircraft Open Die Forging Market involves the deformation of heated metal between simple dies without complete enclosure, a process essential for manufacturing large, high-strength components such as landing gear cylinders, engine shafts, and structural beams. The primary drivers supporting market growth include the resurgence in commercial aviation production rates and the critical necessity for fatigue-resistant parts to support fleet modernization programs. According to the General Aviation Manufacturers Association, in 2024, business jet shipments increased by 4.7% to reach 764 units, underscoring the robust demand for the specialized forged assemblies required in these aircraft.

However, a significant challenge impeding market expansion is the volatility of raw material costs, particularly for titanium and nickel-based alloys which are fundamental to aerospace applications. Supply chain bottlenecks and fluctuating prices for the high energy input required for the forging process further strain operational margins. These constraints can extend production lead times, creating difficulties for manufacturers attempting to align with the aggressive delivery schedules mandated by major original equipment manufacturers.

Key Market Drivers

The surge in global commercial aircraft manufacturing and deliveries constitutes a primary growth engine for the open die forging market, as the process is critical for producing high-strength components like landing gear cylinders and engine shafts. As airlines aggressively modernize fleets to improve fuel efficiency and meet recovering passenger demand, the need for fatigue-resistant forged titanium and superalloy parts has intensified. This heightened production activity is clearly reflected in recent OEM output figures. According to Airbus, January 2025, in the 'Airbus reports 766 commercial aircraft deliveries in 2024' update, the manufacturer delivered 766 commercial aircraft to 86 customers throughout the year, underscoring the immense pressure on the forging supply chain to support escalating build rates.

Simultaneously, escalating defense budgets for military fleet modernization are driving significant demand for specialized open die forgings used in next-generation fighter jets and strategic bombers. Governments worldwide are increasing spending to enhance air superiority capabilities, directly translating into orders for robust airframe structures and propulsion components. According to the Stockholm International Peace Research Institute, April 2025, in the 'Trends in World Military Expenditure, 2024' fact sheet, global military expenditure rose by 9.4% to reach a record $2.7 trillion in 2024, a surge largely attributed to equipment upgrades and geopolitical tensions. This robust environment is bolstering the financial performance of key suppliers; according to Howmet Aerospace, in 2024, the company’s Engineered Structures segment reported an 11% year-over-year revenue increase in the third quarter, highlighting the strong market appetite for advanced aerospace forged products.

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Key Market Challenges

The volatility of raw material costs, particularly for titanium and nickel-based alloys, combined with persistent supply chain bottlenecks, constitutes a significant barrier to the growth of the Global Aircraft Open Die Forging Market. These constraints introduce severe unpredictability into manufacturing operations, where fluctuating prices for high energy inputs and essential metals erode profit margins and complicate the execution of long-term contracts. Furthermore, the scarcity of these critical resources forces manufacturers to extend production lead times, making it increasingly difficult to meet the aggressive delivery schedules mandated by major aerospace original equipment manufacturers.

This operational strain restricts the industry's ability to capitalize on rising orders, effectively capping the volume of finished components that can be delivered to the assembly lines. The impact of these delays is evident in the accumulation of unfulfilled orders across the broader aviation sector. According to the International Air Transport Association, in 2024, the global commercial aircraft backlog reached a historic high of over 17,000 aircraft, a situation driven largely by these pervasive supply chain disruptions and material shortages. This substantial backlog demonstrates that while demand is robust, the forging market's actual expansion is being mechanically restricted by the inability to secure necessary inputs and maintain efficient production rates.

Key Market Trends

The strategic modernization of production facilities through the adoption of digital process simulation and automated open die systems is a dominant trend, enabling manufacturers to produce complex geometries with greater precision. Companies are aggressively replacing aging infrastructure with digitized forging lines that utilize real-time sensor data to minimize machining allowances and enhance structural integrity for defense and nuclear applications. This shift toward recapitalization is evident in major facility upgrades designed to secure sovereign manufacturing capabilities. According to The Manufacturer, December 2024, in the 'Sheffield Forgemasters sees over 100% order increase in 2024' article, Sheffield Forgemasters committed £286 million to contracts for its recapitalization program, which includes the construction of the UK's largest automated open-die forging line to replace legacy machinery and improve throughput efficiency.

Simultaneously, the implementation of sustainable and energy-efficient manufacturing has become a critical priority as the industry faces pressure to decarbonize energy-intensive thermal processes. Forging houses are actively decoupling production growth from environmental impact by optimizing furnace operations and adopting low-carbon technologies to meet stringent ESG targets. This focus on reducing the carbon footprint of aerospace components is driving measurable operational changes across the supply chain. According to Howmet Aerospace, April 2025, in the '2024 Environmental, Social and Governance Report', the company achieved a 21.7% reduction in greenhouse gas emissions from its operations compared to a 2019 baseline, a milestone realized through strategic improvements in production process efficiency and energy management.

Segmental Insights

The Large Components segment is the fastest-growing category in the Global Aircraft Open Die Forging Market, driven by the rising production of wide-body commercial and heavy-lift military aircraft. This expansion stems from the critical necessity for massive, single-piece structures such as landing gear cylinders and turbine shafts, which require the exceptional internal grain flow and fatigue resistance unique to open die forging. Since alternative manufacturing methods cannot match the structural integrity necessary for these heavy-load applications, manufacturers increasingly rely on this segment to ensure compliance with the rigorous safety standards mandated by regulatory bodies like the FAA and EASA.

Regional Insights

North America maintains a dominant position in the global aircraft open die forging market, driven by the presence of major aerospace original equipment manufacturers and a robust defense sector. The United States Department of Defense generates consistent demand for high-strength forged components through substantial military aviation procurement programs. Additionally, the region benefits from established manufacturing infrastructure that supports high-volume commercial aircraft production. Strict safety and quality standards enforced by the Federal Aviation Administration further strengthen the local supply chain, ensuring the availability of compliant structural parts for both civil and military applications.

Recent Developments

• In June 2025, Pursuit Aerospace completed the acquisition of Larson Forgings, a manufacturer specializing in seamless rolled rings and open-die forgings. This transaction integrates the acquired company's long-standing forging expertise into the buyer's global operations, broadening its ability to supply complex components for aircraft engines. The expansion aligns with the company's objective to strengthen its manufacturing capabilities and offer a wider range of solutions to the aerospace and defense markets. The move allows the company to better serve its customers by combining complementary manufacturing processes and increasing its production scale.
• In February 2025, Bharat Forge Limited entered into a collaboration with Liebherr-Aerospace & Transportation SAS to establish a new manufacturing facility in India. This partnership aims to produce high-precision components, such as landing gear parts, to address the increasing demand in the global aerospace supply chain. The facility, planned to be operational in 2025, will incorporate advanced technologies including a ring mill and specialized machining equipment. The initiative underscores the company's strategy to expand its footprint in the aviation sector and supply critical forged and machined products to international original equipment manufacturers.
• In July 2024, ATI Inc. announced its membership as a Tier One partner in the Advanced Forming Research Centre (AFRC) to advance aerospace materials and manufacturing technologies. Through this collaboration, the company gains access to the FutureForge facility, which features an industrial-scale tri-modal press offering open-die, closed-die, and isothermal forging capabilities. The partnership focuses on developing new metallic alloys and process innovations to enhance the efficiency and performance of next-generation aircraft engines. This strategic move allows the company to accelerate research into high-strength materials required for demanding aerospace and defense environments.
• In April 2024, Sheffield Forgemasters appointed VINCI Building to construct a new open-die forging facility at its site in Sheffield, United Kingdom. The contract, valued at £138 million, involves the creation of a 13,800 square meter building designed to house a 13,000-tonne heavy forging press. This new line aims to support defense and commercial sectors, including civil nuclear power, by enabling the production of larger forged components. The project is a key part of the company’s recapitalization program, which seeks to modernize its industrial infrastructure and secure long-term manufacturing capabilities for critical heavy engineering applications.

Key Market Players

• Arconic Corporation
• Allegheny Technologies Incorporated
• Precision Castparts Corp.
• PJSC VSMPO-AVISMA Corporation
• Metallus Inc.
• Howmet Aerospace Inc.
• Norsk Titanium AS
• Forgital Italy S.p.A
• Doncasters Limited
• Aubert & Duval

By Aircraft Type	By Application Type	By Component Size Type	By Region
Commercial Aircraft Regional Aircraft Helicopter Military Aircraft General Aviation	Airframe Engine	Small Components Large Components	North America Europe Asia Pacific South America Middle East & Africa

Report Scope:

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

• Aircraft Open Die Forging Market, By Aircraft Type:

• Commercial Aircraft
• Regional Aircraft
• Helicopter
• Military Aircraft
• General Aviation

• Aircraft Open Die Forging Market, By Application Type:

• Airframe
• Engine

• Aircraft Open Die Forging Market, By Component Size Type:

• Small Components
• Large Components

• Aircraft Open Die Forging 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