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The global aero engine composite material market size was valued at USD 3.47 billion in 2024. The market is projected to grow from USD 3.78 billion in 2025 to USD 6.84 billion by 2032, exhibiting a CAGR of 8.83% during the forecast period. North America dominated the aero engine composite material market with a market share of 38.62% in 2024.
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Request SampleComposite materials have been utilized in the aerospace industry for many decades, initially in non-safety critical applications and more recently as primary structures, including fuselage and wing structures on the latest aircraft from Boeing, Airbus, and Bombardier. An ever-growing aerospace market presents major opportunities to the U.K. composite sector to develop products and technologies for current and future platforms, with the capability of composite materials becoming more advanced and suitable for applications across the aircraft environment.
Aircraft engines present an inconsistent and demanding environment for any material system. These aero-engine designs are oriented toward the reduction of fuel consumption, higher thrust, and lighter weight for better fuel efficiency. Furthermore, the introduction of advanced aero-engine composite material requires intensive and advanced development programs. Since 1980, average fuel burn on commercial aircraft has fallen by 27% for a wide body and 35% for a narrow body.
The rising production rate of commercial aircraft composites is driving the growth of the composites market for aircraft engines. Additionally, the use of ceramic and metal matrix composites helps reduce the weight of engines, allowing them to run at higher temperatures. However, the high capital investment and replacement cost of aero-engine composite material may restrain the growth of the market.
Short-Term Impact on Aircraft Deliveries Disrupted the Supply Chain of the Aero Engine Composite Market in 2020-2021
The outbreak of the COVID-19 pandemic and severe lockdown measures had a huge impact on the aviation industry, resulting in a short-term shutdown of flights and disruption in supply chain delays in aircraft and engine deliveries. Following the severe disruptions caused by the COVID-19 pandemic, the aviation industry has rebounded with strong passenger demand and financial growth in 2024. As airlines expand their fleets to meet growing demand, the need for advanced aero engine composite materials is increasing. These materials are essential for enhancing engine performance and fuel efficiency, aligning with the industry's focus on sustainability and reducing carbon emissions. Major manufacturers such as GE Aviation, Safran, Rolls-Royce, and CFM International are actively investing in new technologies to improve engine efficiency and reduce weight through advanced composites.
Rise in Adoption of Composite Material in Technologically Advanced Engines Leads to Fuel Efficient and Lightweight Engines
Technological advances in a variety of composite mixtures are a key trend gaining demand in the aircraft engine composites market. Manufacturers of aero engine composites are increasingly focused on implementing advanced aero engine composite manufacturing techniques that increase engine fuel efficiency and reduce CO2 emissions. Additionally, key players such as GE Aviation, Solvay SA, and Meggitt PLC, among others are focused to enhance their portfolio and manufacture fuel efficient engines using comprehensive technologies to withstand the market competition.
For instance, in August 2024, ÉireComposites, a Galway-based company that is involved in the manufacturing of fiber-reinforced composite materials signed a contract with Avic Sac Commercial Aircraft Co. Ltd. to produce composite components for the Airbus A220. ÉireComposites is also actively involved in innovative projects such as TOSCA, which focuses on sustainable composite aerostructures. Such developments increase the demand for lightweight materials in the aerospace industry. This collaboration is helping the aviation sector to expand the market for composite materials for engines to achieve fuel efficiency.
The aircraft engines with high fuel efficiency reduce the carbon emission and also reduce the operational cost. Additionally, many government organizations have implemented new emission regulations due to which the demand for fuel efficient engines has led to market growth. In September 2024, IATA released its updated policies and Net Zero Roadmaps for the aviation industry. This confirms that the air transport industry can achieve decarbonization by 2050. Clear policy and financial frameworks are going to support the changes needed across all economic sectors, according to IATA's Director General Willie Walsh.
Moreover, Airbus and MTU Aero Engines are actively involved in the development of zero-emission aircraft programs which focus on fuel efficient aircraft engines. Such increased focus toward reducing emission and achieving fuel efficient engines is expected to promote the adoption of composite material in manufacturing of engines.
Growing Application of Composite Materials in Technologically Advanced Engines to Fuel Market Growth
Technological advancements in a variety of composite blends are a key factor contributing to the aero engine composite material market growth. Manufacturers of aero-engine composite materials are significantly focusing on implementing advanced manufacturing techniques that increase engine fuel efficiency and reduce CO2 emissions. Aircraft engines with high fuel efficiency reduce carbon emissions and operational costs.
Additionally, many government organizations have implemented new emission regulations, due to which the demand for fuel-efficient engines has aided the market. Moreover, there is a growing popularity for the use of composite materials, particularly carbon fiber, to design lighter and more fuel-efficient engines. For instance,
Higher Cost Associated with Composite Materials to Hinder the Market Growth
Though composite materials are widely used in the aerospace industry, high manufacturing costs for their production have hampered the growth of the market. Moreover, difficulty in repairing composites as compared to metallic structures is also restraining the market. The higher cost associated with aero-engine composite materials is due to the price of the fiber and the complex process required to manufacture the final output. In addition, it is difficult to determine when the internal structure of composite aircraft components has been damaged, making inspection difficult and costly. The machinery and tools required to manufacture thermoplastic and other composites are cost-intensive and result in high product costs. Hence, it is not commercially viable to adopt composite materials on a large scale. Moreover, the cost of a structural composite damage claim is higher than that of alloy-constructed counterparts.
Increase in Focus on Sustainable Aviation Practices has evolved as an opportunity to reshape the Market
The aviation industry is experiencing a rise in pressure to decrease carbon emissions and improve fuel efficiency. For instance, in October 2022, member states of the International Civil Aviation Organization (ICAO) agreed to a Long-Term Aspirational Goal (LTAG) of net-zero carbon dioxide (CO2) emissions from aviation by 2050. Thus, there is an increase in demand for lightweight materials such as carbon fiber composites. These materials reduce the weight and contribute to achieving lower fuel consumption. This further helps to enhance the performance of aircraft engines.
Thus, as the aviation industry focuses on carbon emission reduction, there is high dependence on lightweight composite material to meet the need for more fuel-efficient aircraft. Moreover, the adoption of advanced composite materials aligns with regulatory standards that are enacted to reduce environmental impact. Therefore, it encourages companies to invest in and develop innovative composite technologies for aero engines. This shift toward sustainability presents significant growth opportunities for composite material in the aircraft engine market.
Higher Aircraft Production Rates, Requiring Efficient Composite Processing Capabilities to Create Market Opportunities for Aero Engine Composite Material Market
In recent times, there is a rising affluence of air travel on account of rising per capita income of the global population, growing investments in the aviation infrastructure by key players, and the rising demand for planes from the commercial and military & defense sector. In the year 2024, Airbus’s commercial aircraft deliveries increased by 4.2 percent to 766. According to an announcement from Airbus, its commercial aircraft business registered 878 gross new orders. Moreover, Boeing and Airbus are planning to more than double their 2024 production rates of 787s and A350s by 2026.
Additionally, with the rise in air travel there is a demand to modernize the aircraft fleet. For instance, in March 2025, EVA Air expanded its Airbus fleet commitment by exercising options for six additional A350-1000s and three A321neos, valued at USD 3.1 billion. Such modernization increases the need for installation of advanced technology to make them fuel-efficient. Owing to this there is an increase in adoption of efficient composite processing capabilities by key players. Furthermore, to minimize cost and weight key players involved in the market are using a feasible way by improving the capacity of thermoplastics to be fusion welded by resistance or induction welding techniques
For example, the tail assembly for the G650 Business Jet by Gulfstream through Fokker Aerostructure was made using induction welding. This construction achieved 10% saved weight and 20% reduced costs over thermoset composite structure. Furthermore, in an experiment Boeing demonstrated the use of carbon-fiber reinforced polymer composite in the airframe of Boeing 787 airplane where the composite materials contributed to reduced fuel consumption and carbon dioxide reduction by at least 14% to 15%.
Owing to this, many key players such as GE aviation, Safran, and Airbus are planning to adopt composite materials in the new generation aircrafts creating market opportunities for the aero engine composite material market.
Certification and Supply Chain Challenges in Aero Engine Composites
Certification challenges stem from composites sensitivity to defects such as low-energy impact damage, requiring rigorous testing to meet aviation safety standards. Unlike metals, internal flaws (e.g., delamination, fiber misalignment) demand advanced non-destructive testing (NDT) methods, increasing costs and timelines. Regulatory bodies mandate extensive environmental and performance validations, particularly for novel materials such as ceramic matrix composites (CMCs), prolonging R&D cycles. Moreover, the market also experiences the supply chain issues arise from high dependence on specialized raw materials (e.g., carbon fibers, resins), sourced from limited global suppliers, creating bottlenecks. Geopolitical disruptions and logistics delays causes material shortages, inflating costs and production risks. High-temperature curing processes and precision layering require niche equipment, straining smaller manufacturers. Such factors are expected to create challenges that hinder the growth of the market.
R&D initiatives (Historically and Present) by Major Players Manufacturing Aero Engines and Aero Engine Components
High Adoption of Ceramic Matrix Composite in Hot Section of Engine to Boost Market Growth
Ceramics and ceramic-metal mixtures are used in the hot section of the engine, majorly referred to as combustion chambers due to their high heat resistance. They have high melting points and do not require cooling systems; hence, they are used for manufacturing lighter, less complicated engine parts. Ceramics is the most vital part of the aero engine composite material business, as a number of scientific and manufacturing innovations use this material to create Ceramic Matrix Composites (CMC). These are also highly advanced and exhibit high hardness and strength without losing their superior heat treatment properties of ceramic and glass. Composites of Silicon Carbide (SiC), ceramic fibers, ceramic resin, and CMCs are manufactured using a sophisticated process and are further enhanced with proprietary coatings. Key players involved in the market are taking initiatives and spending more on material development techniques to boost their sales. For instance,
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Commercial Aircraft Segment held the Highest Position in the Market due to Rise in Demand for Modern Generation Engine
Based on application, the market is segmented into commercial aircraft, military aircraft, and general aviation aircraft.
Commercial aircraft was the largest segment, with a significant aero-engine composite market share in 2024. The rising demand for commercial and modern generation aircraft engines due to growing air passenger traffic is anticipated to fuel the market growth. Moreover, airline operators accept concepts of low-cost subsidiary airlines to increase their revenue. Thus, higher segment growth is projected during the forecast period. The demand for composite materials in aero engines is particularly strong in the narrow-body aircraft segment, such as the A320neo, while wide-body aircraft also benefit from these materials for enhanced efficiency. In addition, various aircraft engine manufacturers are focusing on the expansion of commercial aircraft engine production in response to the increase in global demand. For instance, in September 2024, Safran, an aircraft engine manufacturer, announced the expansion of its LEAP engine production capacity in Querétaro, Mexico, to produce commercial aircraft engines. LEAP engine is designed with composite materials, particularly 3D woven carbon fiber composites, primarily for its fan blades and fan case. Such expansion strategies ramp up the production of composite material aircraft engines, stimulating the growth of the market during the forecast period.
Military aircraft is the emerging segment in the market owing to increased procurement of military aircraft due to high defense expenditure and increased popularity of high bypass engines in military aircraft. Moreover, the increased demand for aircraft for surveillance applications in the military boosts the segment growth. Several military aircraft use composite material for various components of engines, such as fan blades, bypass ducts, and others. For instance, in June 2024, GE Aerospace and Hindustan Aeronautics Limited announced a collaboration to produce advanced fighter jet engines. According to officials, the bypass duct of the engine will be made from polymer matrix composite material. Such developments drive the adoption of composite material in manufacturing aircraft engines, which is expected to fuel the segment's growth.
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Engine Casing Segment to Dominate Market Due to High Demand for Lightweight Engine Cowls
Based on component, the market is segmented into fan blades, guide vanes, shrouds, engine casing, engine nacelle, and other cold end parts.
The engine casing segment is expected to dominate the market during the forecast period. The expansion of the aerospace industry with increasing demand for lightweight aircraft is leading to the development of lightweight engine casings and cowls made up of composite materials such as carbon fiber. Moreover, the modern generation engine casing is designed to reduce the noise produced by the engine to a greater extent. In addition, there is a rise in demand for composite material to manufacture various parts of aircraft engines including engine casing. For instance, in November 2023, Rolls-Royce ran its UltraFan engine, the world’s largest jet engine, at full power using 100% Sustainable Aviation Fuel (SAF) at its Testbed 80 facility in Derby, U.K. The UltraFan is 10% more efficient than the Trent XWB and incorporates advanced technologies such as carbon titanium fan blades, composite casings, and Ceramic Matrix Composites (CMCs). The UltraFan’s use of lightweight composite materials like carbon titanium fan blades and CMCs reduces engine weight and enhances thermal efficiency, driving demand for advanced composites.
Fan blades are the emerging segment owing to the growing demand for fan blades to power both narrow-body and wide-body engines. These engines are light in weight and provide a high thrust-to-weight ratio. For instance, the GE90 fan blades are made of carbon-fiber composite and are the world’s largest and most powerful jet engine. The fan blade segment is expected to grow significantly as there is an increase in demand for various composite engine components for reducing engine weight and improving fuel efficiency. For instance, in January 2025, Shanghai Aero Engine Composites Co., Ltd. (Shangfa Composites) completed the production of its first composite fan blade. Such developments stimulate the production of advanced materials to obtain lighter, more fuel-efficient engines with better aerodynamic performance.
The engine nacelle segment is anticipated to grow significantly during the forecast period. This growth is attributed to increased demand for aircraft with advanced nacelle systems and solutions. Composite nacelles are designed for lower weight to provide better engine fuel economy, thus boosting the segment growth. Moreover, the increased R&D for a sustainable aviation future also contributes to growth. The growth of the engine nacelle segment is attributed to increasing demand for composite nacelles. In November 2024, GKN Aerospace announced that it delivered two C-27J nacelles to Leonardo Aircraft. The composite components of nacelles are produced at GKN Aerospace’s Cowes manufacturing site.
Owing to High-temperature Absorbing Capabilities, Carbon Matrix Composite Segment is Expected to Witness High Growth during the Projection Period
Based on composite type, the market is segmented into polymer matrix composites, carbon matrix composites, and metal matrix composites.
The carbon matrix composites segment is estimated to witness higher growth rates during the projection period 2025-2032. Increasing demand for carbon matrix composites for modern engine casing applications in commercial and military aircraft boosts segment growth. Moreover, carbon matrix composites are a unique kind of aero engine composite material that consists of carbon fibers embedded in a carbonaceous matrix. Carbon is an excellent high-temperature material. Carbon fiber is used everywhere in aircraft; for instance, the Boeing 787 Dreamliner passenger plane is composed of 50% composite material by weight, with most of the composite material being carbon fiber laminate or carbon fiber sandwich. Companies such as GE Aviation have been using CMCs in commercial engines. They have successfully implemented CMC components in the LEAP engine, which powers Airbus A320neo and Boeing 737 MAX aircraft. Moreover, aircraft manufacturers are increasingly adopting CMCs in aircraft engines due to their high-temperature resistance, lightweight properties, and potential to improve fuel efficiency. For instance, in October 2024, Bombardier announced significant progress in the production of its highly anticipated Global 8000 business jet. The Global 8000's engine features GE Aviation's oxide-oxide (Ox-Ox) CMCs, which are part of the Passport engine.
The polymer matrix composites segment held a significant market share in 2024 and was estimated to show remarkable growth during the forecast period. The advanced polymer matrix composites have high shock absorbance capacity and innovative structure design, hence providing more safety to the engine and aircraft. Thus, the demand for polymer matrix composite is expected to increase due to its properties.
The growing use of metal matrix composite due to its high strength, stiffness, and low density compared to nickel- and steel-based materials boost segment growth. Titanium Metal-Matrix Composites (MMC) are widely used for engine applications owing to their excellent high-temperature longitudinal strength.
Carbon Fiber Segment dominates the Market Owing to Its Lighter-Weight Properties
Based on fiber type, the market is segmented into carbon fibers, ceramic fibers, and glass fibers.
The carbon fibers segment is estimated to be the largest segment in the aero engine composite material market. Growing demand for lightweight fan blades made up carbon fiber to boost segment growth. Moreover, these modern generation carbon fiber fan blades are now advanced, light weight and made of sustainable material. The low weight and high strength of carbon fiber material reduce the overall weight of aircraft components, leading to improved fuel efficiency and lower emissions. This is particularly critical in meeting stringent environmental regulations and operational cost reductions.
The ceramic fibers segment held a market share of 31.46% in 2024. The segment is projected to grow at the highest compound annual growth rate of 8.61% through the forecast period. The growth of the segment is attributed to the high adoption of ceramic fibers for exhaust nozzle of the aero engine to boost the segment growth,
The market is segmented into North America, Asia Pacific, Europe, and the rest of the world.
North America Aero Engine Composite Material Market Size, 2024 (USD Billion)
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North America dominated the market in 2024 and stood at USD 1.34 billion in 2024. This growth is attributed to the presence of a large number of players manufacturing aircraft and engine components. In addition, the U.S. government is investing in the quality and effectiveness of transport aircraft and their engines, which is expected to fuel the growth of the market. There is also an increase in defense investment in the procurement of combat aircraft, military helicopters, single-engine aircraft, and rescue helicopters. Furthermore, companies such as GE Aviation and Pratt & Whitney are key players in North America. Pratt & Whitney's GTF (Geared Turbofan) engine incorporates advanced composites to enhance efficiency and reduce emissions. Thus, the rise in the production of engines manufactured by these companies is expected to drive the growth of the aero-engine composite material industry. The growth of aero engine composite material is attributed to the heavy investment by various countries in the region for manufacturing advanced aerospace materials.
The U.S. aero engine composite material market is expanding, driven by the aerospace sector’s push for lightweight, fuel-efficient engines to meet stringent environmental regulations and reduce operational costs. For instance, in March 2025, GE Aerospace, an aircraft engine manufacturer, announced to invest USD 1 billion in its U.S. factories and supply chain in 2025. The initiative was taken by the company to increase manufacturing capacity and support the development of advanced materials for the aircrafts. More than USD 100 million will be allocated toward scaling production of next-generation aerospace materials, including Ceramic Matrix Composites (CMCs) and additive manufacturing technologies. Composite materials such as carbon fiber-reinforced polymers (CFRPs) and ceramic matrix composites (CMCs) are increasingly used in engine components in the U.S. such as fan blades, casings, and combustion chambers to enhance durability, heat resistance, and weight reduction.
Europe’s aviation industry plans to double passenger traffic by 2050 to meet the air travel demand. The push for efficiency and reduced emissions drives demand for lightweight composite materials such as carbon fiber and ceramic matrix composites in aero engines. Presence of key players such as Rolls Royce and Safran in Aero Engine manufacturers and presence of composite material manufacturers have created demand for aero engine composites from this region with possibilities for growth across Europe. These materials improve fuel efficiency and enable compatibility with SAFs by reducing engine weight and enhancing performance. Key players involved in the market are setting up plants to manufacture composite engine components. For instance, in September 2024, GKN Aerospace announced the expansion of its aero-engines manufacturing facility in Trollhättan, Sweden, by adding a new 5,000-square-meter production area. GKN Aerospace has extensive experience in manufacturing engine components such as fan outlet guide vanes from Carbon Fiber-Reinforced Polymers (CFRP).
Asia Pacific aero engine composite material market share is expected to grow significantly due to an increase in aircraft deliveries and a rise in travel demand. The Asia Pacific market is expected to grow at the highest CAGR during the forecast period. Air passenger traffic in Asia Pacific is leading to the need for new aircraft and modern-generation engines. Moreover, improving the economy and increasing defense expenditures in emerging countries such as India and China boost the market growth in the region. In addition to the rising military budget, a surge in demand for new aircraft from China and India is expected to fuel the growth of the market.
In addition, the market growth in the rest of the world will witness higher growth figures due to the development of the aerospace sector in the Middle East & Africa due to the large number of commercial airlines registered in the region. The growing investments by Middle East & African airlines for aircraft and engine procurement will fuel the market growth during the forecast period.
Strong Product Portfolio of the Key Players to Lead the Market
The market is highly consolidated as a few companies control the large market share. GE Aviation, a subsidiary of General Electric Company, is a leading supplier of turboprop and jet engines. With outstanding product technology and a diversified product portfolio, the company aims to dominate the world market. The competitive landscape of the aero engine composite material market includes key players such as Rolls Royce Holdings Plc., Safran SA, Meggitt Plc, and others. The introduction and upgrading of advanced aero engine composite material processing technologies to offer their customers an improved product portfolio is the key strategy of the major players in the market.
The research report offers a detailed analysis of the market and focuses on key aspects such as leading companies, product types, and leading applications of the product. Additionally, the report provides insights into the market trends and market revenue and highlights key industry developments. In addition to the factors mentioned above, the report encompasses several factors that have contributed to the growth of the market in recent years.
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ATTRIBUTE | DETAILS |
Study Period | 2019-2032 |
Base Year | 2024 |
Estimated Year | 2025 |
Forecast Period | 2025-2032 |
Historical Period | 2019-2023 |
Unit | Value (USD Billion) |
Segmentation | By Application
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By Component
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By Composite Type
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By Fiber Type
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By Region
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Fortune Business Insights says that the global market size was USD 3.47 billion in 2024 and is projected to reach USD 6.84 billion by 2032.
Registering a CAGR of 8.83%, the market will exhibit steady growth during the forecast period (2025-2032).
The commercial segment is expected to lead this market during the forecast period.
GE Aviation is the leading player in the global market.
North America dominated the market in terms of share in 2024.
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