Aeroengine Composites Market Size and Share
Market Overview
| Study Period | 2019 - 2030 |
|---|---|
| Market Size (2025) | USD 3.57 Billion |
| Market Size (2030) | USD 6.14 Billion |
| Growth Rate (2025 - 2030) | 11.46% CAGR |
| Fastest Growing Market | Middle East and Africa |
| Largest Market | Asia Pacific |
| Market Concentration | Medium |
Major Players
*Disclaimer: Major Players sorted in no particular order Image © Mordor Intelligence. Reuse requires attribution under CC BY 4.0. |
|
Aeroengine Composites Market Analysis by Mordor Intelligence
The aeroengine composites market is valued at USD 3.57 billion in 2025 and is forecasted to reach a market size of USD 6.14 billion by 2030, advancing at an 11.46% CAGR. Growing fleet renewal, decarbonization mandates, and rising fuel prices push airlines and engine makers toward lighter propulsion systems that cut fuel burn by up to 20% while meeting stricter emission limits. Ceramic matrix composites (CMC) now withstand 1,300°C, allowing higher core temperatures and improved thermal efficiency. Automated fiber-placement and out-of-autoclave curing are lowering the cost per pound by nearly 30%, making composites economically viable for narrowbody programs. Supply-chain resilience remains critical after GE Aerospace’s 10% delivery shortfall in 2024 exposed bottlenecks in high-pressure turbine blade sourcing.
Key Report Takeaways
- By application, commercial aviation held 70.05% of the aeroengine composites market share in 2024, while the military segment is expected to grow the fastest at a 12.74% CAGR to 2030.
- By component, fan blades accounted for 37.98% of the aeroengine composites market size in 2024; fan cases are projected to expand at a 13.48% CAGR through 2030.
- By material, polymer matrix composites retained 63.50% share in 2024, whereas ceramic matrix composites are set to record a 15.05% CAGR to 2030.
- By end-user, OEMs dominated with 86.76% revenue share in 2024; the aftermarket is forecast to rise at an 11.80% CAGR through 2030.
- By geography, Asia-Pacific led with a 32.18% share in 2024, while the Middle East and Africa region is anticipated to grow at a 13.15% CAGR to 2030.
Global Aeroengine Composites Market Trends and Insights
Drivers Impact Analysis
| Driver | (~) % Impact on CAGR Forecast | Geographic Relevance | Impact Timeline |
|---|---|---|---|
| Shift toward lightweight, fuel-efficient propulsion systems | +2.8% | Global | Medium term (2-4 years) |
| Ramp-up of LEAP and GEnx engine production volumes | +3.2% | North America and Europe | Short term (≤2 years) |
| Decarbonization roadmaps driving high-temperature CMC demand | +2.1% | EU and North America | Long term (≥4 years) |
| Shifting aftermarket spend toward composite replacement parts | +1.4% | Asia-Pacific | Medium term (2-4 years) |
| Cost reductions from automated manufacturing processes | +1.7% | North America and Europe | Short term (≤2 years) |
| Increasing funding for hypersonic and 6th-gen fighter manufacturing | +0.9% | North America | Long term (≥4 years) |
| Source: Mordor Intelligence | |||
Shift toward lightweight, fuel-efficient propulsion systems
Airlines need 15-20% fuel savings to offset volatile fuel prices, driving a rapid pivot toward composites that cut nacelle weight and boost bypass ratios. GE Aerospace’s RISE open-fan demonstrator targets 20% CO₂ reductions using carbon-fiber fan blades with bypass ratios up to 60.[1]GE Aerospace, “RISE Program Fact Sheet,” geaerospace.com Airbus is flight-testing carbon-fiber reinforced thermoplastic structures that pair with 100% sustainable aviation fuel and promise 20% fuel burn cuts. Narrowbody output above 100 aircraft per month heightens the urgency for scalable, automated composite production.
Ramp-up of LEAP and next generation aircraft engine production volumes
Over 4,000 aircraft fly with LEAP engines, prompting Safran to invest EUR 1 billion (USD 1.16 billion) in new MRO facilities in Brussels, Hyderabad, Querétaro, and Casablanca to handle 1,200 annual shop visits by 2028.[2]Safran Aircraft Engines, “Safran Invests in Global LEAP MRO Network,” safran-aircraft-engines.com GE earmarked EUR 64 million (USD 74.05 million) for European test cells and tooling that support the LEAP and GE9X programs. Component shortages, chiefly high-pressure turbine blades, trimmed 2024 engine deliveries by 10% despite USD 26.9 billion in commercial revenue, underscoring the need for diversified composite supply chains.
Decarbonization roadmaps driving high-temperature CMC demand
CMCs enable turbine inlet temperatures 500°F hotter than metal parts, raising thermal efficiency. Using rotating CMC components, GE’s XA100 adaptive-cycle engine shows 25% fuel savings and 30% range gains. More than 100,000 GE CMC shrouds have logged 10 million flight hours, demonstrating durability at scale. Mitsubishi Chemical’s 1,500°C carbon-fiber-based CMC for space applications illustrates widening performance envelopes in pursuit of net-zero flight.
Shifting aftermarket spend toward composite replacement parts
Airlines are shifting from price-focused spares to total-cost-of-ownership strategies that leverage composites’ longer on-wing life. Safran’s purchase of Component Repair Technologies positions it to capture demand for composite part refurbishment as LEAP shop visits accelerate. Asia-Pacific carriers with high utilization hours are early adopters of composite repairs that slice fuel burn and extend maintenance intervals.
Restraints Impact Analysis
| Restraint | (~) % Impact on CAGR Forecast | Geographic Relevance | Impact Timeline |
|---|---|---|---|
| Brittleness and inspection complexity of CMCs | −1.8% | North America and Europe | Medium term (2-4 years) |
| Limited high-temperature resin supply base | −1.2% | North America and Europe | Short term (≤2 years) |
| Volatile build-rates deferring CAPEX on new lines | −1.6% | North America | Short term (≤2 years) |
| Protracted qualification cycles under FAA/EASA Part 21 rules | −2.1% | US and Europe | Long term (≥4 years) |
| Source: Mordor Intelligence | |||
Brittleness and inspection complexity of CMCs
CMC fan blades risk foreign object damage because their ceramic microstructure can crack under impact loads. Traditional ultrasonic or X-ray methods struggle to detect microcracks, forcing OEMs to invest in computed-tomography scanning and specialist training. New machining methods using polycrystalline diamond tools cut processing time by 70%, raising capital costs and making adoption harder for smaller suppliers.
Protracted qualification cycles under FAA/EASA Part 21 rules
Novel materials can take 5-7 years to qualify. Each resin tweak requires retesting for fatigue, thermal cycling, and environmental durability, stalling the entry of promising CMC grades. Digital twin certification is being explored, but regulators have yet to accept simulation-only evidence, so engine makers stick with proven composites to avoid delays.
Segment Analysis
By Application: Commercial Aviation Drives Volume Growth
Commercial engines captured 70.05% of the aeroengine composites market share in 2024 because thousands of LEAP and GEnx units integrate composite fan blades and cases that deliver up to 20% fuel savings.[3]CFM International, “LEAP Engines Reach 4,000 Aircraft Milestone,” cfmaeroengines.com The aeroengine composites market size tied to military programs will expand the fastest at a 12.74% CAGR through 2030 as XA100-class propulsion and hypersonic demonstrators adopt CMC shrouds.
Business jets and regional aircraft operators are beginning to retrofit composite-rich engines as technology migrates downstream. Partnerships like GE Aerospace and Kratos Defense plan small-class engines that marry CMC turbines with affordable production methods, widening the customer base. This diffuses risk across civil and defense budgets, improving supplier order stability.
Note: Segment shares of all individual segments available upon report purchase
By Component: Fan Blades Lead, Fan Cases Accelerate
Fan blades retained 37.98% of 2024 revenue because carbon-fiber construction delivers high stiffness-to-weight and reduces inertia for better thrust response. Fan cases are projected to grow at 13.48% CAGR, lifting the aeroengine composites market size for containment hardware as regulatory containment tests favor composite shells.
Integrating shrouds, guide vanes, and O-ring seals into monolithic composite structures will keep margins healthy by reducing part count and assembly hours. Suppliers with AFP capability can machine complex aerofoils in a single pass, enhancing performance consistency.
By Material Type: PMC Dominance, CMC Acceleration
Polymer matrix composites held a 63.50% share in 2024 owing to entrenched supply chains and proven process repeatability. Ceramic matrix composites will outpace at a 15.05% CAGR, lifting the aeroengine composites market size for high-temperature sections, such as shrouds, liners, and exhaust plugs migrate to CMC.
Hybrid lay-ups that bond PMC fan blades to CMC leading edges are under evaluation to balance cost with heat resistance. The global resin shortage remains a near-term risk because only a handful of suppliers produce aerospace-qualified phenolics.
Note: Segment shares of all individual segments available upon report purchase
By End-User: OEM Dominance, Aftermarket Momentum
OEMs controlled 86.76% of 2024 revenue because composites are embedded at the design stage and purchased with new engines. The aftermarket is forecast at an 11.80% CAGR; airlines now pay premiums for composite spares that cut fuel costs and extend on-wing time.
Safran’s EUR 1 billion (USD 1.16 billion) MRO expansion aims to capture this spending shift through regional repair hubs that process composite fan blades and cases, reducing shipping time for Asia-Pacific operators. Predictive health-monitoring tools further boost aftermarket adoption by quantifying real-time fuel savings.
Geography Analysis
Asia-Pacific held a 32.18% share in 2024 as China accelerated Indigenous programs like the CJ-1000 for the C919 and the 35-ton-thrust CJ-2000, which are rich in composite hot-section parts. China’s turbine blades now tolerate 1,700 °C through single-crystal casting and 3D-printed cooling channels. Japan and South Korea supply high-strength fibers and prepregs, while India’s widebody orders boost regional demand.
North America remains a technology leader. GE Aerospace’s USD 26.9 billion commercial engines revenue in 2024 stemmed from composite-laden LEAP and GEnx programs, though material shortages cut deliveries by 10%. NASA’s HyTEC initiative is coating CMC airfoils to raise single-aisle efficiency, sustaining R&D pipelines.
The Middle East and Africa is projected to witness the fastest growth at 13.15% CAGR as the Gulf carriers add composite-rich engines and regional forces invest in next-generation fighters. Safran-MTU’s EURA engine will anchor European helicopter upgrades, while EU Clean Aviation’s open-fan demonstrator supports 20% CO₂ cuts via large-diameter composite fans.[4]Clean Aviation, “Open Fan Demonstrator Targets 20% CO₂ Cuts,” clean-aviation.eu
Competitive Landscape
Market concentration is moderate. GE Aerospace, CFM International, Pratt & Whitney, and Rolls-Royce plc dictate engine architectures. Still, composite part supply is fragmented across Hexcel, Solvay, Toray, and a growing field of specialist fabricators. GE’s partnership with Kratos Defense aims to leverage small-engine expertise for unmanned systems, signaling intent to diversify revenue streams.
Safran’s acquisition of Component Repair Technologies underscores consolidation in the MRO space, where control of composite repair know-how secures recurring income. Patent filings emphasize process innovation, such as magnetic advanced jet turbines that embed CMC for extreme heat tolerance. Disruptors such as iCOMAT target double-digit weight savings through rapid tape shearing, enticing airframers seeking faster cycle times.
Supply-chain resilience is now a key differentiator. Firms with vertically integrated fiber, resin, and part production can better buffer raw-material shocks than traders who rely on spot markets. Long-term agreements with airframers and Tier-1 suppliers are becoming prerequisites for investment in new AFP lines.
Aeroengine Composites Industry Leaders
-
CFM International
-
Rolls-Royce plc
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Pratt & Whitney (RTX Corporation)
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Safran SA
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GE Aerospace (General Electric Company)
- *Disclaimer: Major Players sorted in no particular order
Recent Industry Developments
- March 2025: China Aero Engine Corporation unveiled the CJ-2000 engine with 35-ton thrust capability. The engine demonstrates 15% higher fuel efficiency than the GEnx model and incorporates single-crystal blades operating at 1,700 °C. The engine's 3D-printed combustor reduces weight by 12%.
- March 2024: GE Aerospace announced its plans to invest EUR 64 million (USD 73.98 million) in European manufacturing facilities to enhance commercial and military engine production through advanced techniques and materials. The company aims for lighter components that improve efficiency and reduce emissions.
- October 2023: GKN Aerospace expanded its partnership with GE Aerospace, becoming the sole supplier of fan cases for GEnx, CF6, and GE90 engines, while securing 50% of GE9X fan case assembly throughout the program duration.
Research Methodology Framework and Report Scope
Market Definitions and Key Coverage
Our study defines the aeroengine composites market as the annual value of polymer- and ceramic-matrix composite parts that are factory-installed in fixed-wing aircraft gas-turbine engines, covering fan blades, fan cases, guide vanes, shrouds, combustor liners, and nacelle hot-end structures.
Helicopter turboshafts and composite structures outside the propulsion system, such as wings or interior panels, are excluded.
Segmentation Overview
- By Application
- Commercial Aircraft
- Narrow-Body
- Wide-Body
- Regional Jet
- Military Aircraft
- General Aviation Aircraft
- Business Jet
- Others
- Commercial Aircraft
- By Component
- Fan Blades
- Fan Case
- Guide Vanes
- Shrouds
- Other Components
- By Material Type
- Polymer Matrix Composites (PMC)
- Ceramic Matrix Composites (CMC)
- By End-User
- OEM
- Aftermarket
- By Geography
- North America
- United States
- Canada
- Mexico
- Europe
- United Kingdom
- France
- Germany
- Italy
- Rest of Europe
- Asia-Pacific
- China
- India
- Japan
- South Korea
- Rest of Asia-Pacific
- South America
- Brazil
- Rest of South America
- Middle East and Africa
- Middle East
- Saudi Arabia
- United Arab Emirates
- Rest of Middle East
- Africa
- South Africa
- Rest of Africa
- Middle East
- North America
Detailed Research Methodology and Data Validation
Primary Research
Engine OEM engineers, Tier-1 composite suppliers, airline MRO managers, and regional composite trade associations were interviewed across North America, Europe, and Asia-Pacific. These discussions clarified material qualification timelines, aftermarket replacement cycles, and average selling prices, which in turn grounded model assumptions.
Desk Research
Mordor analysts reviewed public data from agencies such as the Federal Aviation Administration, EASA, and the International Trade Administration, alongside aircraft build-rate statistics from Airbus and Boeing order books, procurement releases posted by the U.S. Department of Defense, and peer-reviewed articles indexed in ScienceDirect that detail ceramic-matrix performance. Paid databases, D&B Hoovers for supplier revenues and Dow Jones Factiva for deal flow, supplied financial context. Customs records retrieved through Volza helped gauge cross-border shipments of composite fan cases. This list is illustrative; numerous additional documents informed data gathering and verification.
Market-Sizing & Forecasting
A blended top-down and bottom-up framework was built. Top-down reconstruction began with single-aisle and wide-body engine deliveries, adjusted for composite penetration rates, average unit weights, and primary material cost indices; sampled ASP × volume roll-ups from supplier disclosures then cross-checked totals and fine-tuned segment splits. Key variables include LEAP and GEnx monthly production, ceramic-matrix capacity additions, aviation fuel price trends, and air-traffic rebound indicators that steer aftermarket demand. Five-year projections use a multivariate regression that relates composite content per thrust class to forward build-rate guidance and material cost curves validated by expert consensus, with ARIMA smoothing applied where data gaps exist.
Data Validation & Update Cycle
Outputs undergo variance checks against historical composite-to-thrust ratios, peer benchmarks, and prior editions. Senior reviewers sign off after anomalies are resolved, and the model is refreshed each year, with interim updates triggered by material events such as engine program rate changes or major composite qualification milestones.
Why Our Aeroengine Composites Baseline Commands Reliability
Published estimates diverge because firms pick different scopes, cost bases, and refresh cadences.
External studies place 2025 values as low as USD 2.97 billion and as high as USD 4.79 billion.
Benchmark comparison
| Market Size | Anonymized source | Primary gap driver |
|---|---|---|
| USD 3.57 B (2025) | Mordor Intelligence | - |
| USD 2.97 B (2025) | Global Consultancy A | Extends historic CAGR without factoring LEAP and CMC acceleration |
| USD 4.79 B (2025) | Industry Study B | Aggregates broader aerospace composites, limited engine filtration |
In sum, by centering on propulsion-specific composite volumes, validating inputs with production line intelligence, and maintaining an annual refresh, Mordor Intelligence offers decision-makers a balanced, transparent baseline that they can readily audit and replicate.
Key Questions Answered in the Report
Why are composites increasingly used in commercial aero-engines?
Composites cut engine weight, allow higher temperatures, and enable 15-20% fuel savings, helping airlines meet cost and emission goals.
How large is the aeroengine composites market in 2025?
The aeroengine composites market size stands at USD 3.57 billion in 2025 and is projected to reach USD 6.14 billion by 2030 at an 11.46% CAGR.
Which segment grows fastest within the market?
The military application segment posts the highest growth, with a 12.74% CAGR through 2030 as adaptive-cycle and hypersonic programs scale.
What challenges hinder wider adoption of CMCs?
Key barriers include brittleness, complex nondestructive inspection, limited high-temperature resin supply, and lengthy FAA/EASA qualification cycles.
Which region leads demand for aeroengine composites?
Asia-Pacific leads with 32.18% market share, driven by China’s indigenous engine programs and rising commercial jet deliveries.
How are cost reductions achieved in composite manufacturing?
Automated fiber-placement, rapid tape shearing, and snap-cure prepregs cut lead times by up to one-third and reduce cost per pound by about 30%.
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