Aerospace 3D Printing Market: Applications in Aircraft Manufacturing

The global aerospace 3D printing market size was estimated at USD 3.13 billion in 2023 and is projected to reach USD 11.38 billion by 2030, growing at a CAGR of 20.6% from 2024 to 2030. The demand for customization and rapid prototyping is driving the adoption of 3D printing in the aerospace sector.

Additive manufacturing enables rapid iteration and customization of aerospace components, allowing manufacturers to quickly iterate designs, test prototypes, and accelerate the product development cycle. This agility is particularly valuable in the aerospace industry, where rapidly prototyping and iterating designs can significantly reduce time-to-market and enable faster innovation in aircraft and spacecraft development.

The COVID-19 pandemic had a negative impact on market growth. One of the immediate effects of the pandemic was the disruption of global supply chains, leading to delays in the manufacturing and delivery of aerospace components. Moreover, the pandemic underscored the importance of resilience and adaptability in aerospace manufacturing. As airlines grounded fleets and reduced orders for new aircraft in response to decreased air travel demand, aerospace manufacturers faced declining revenues and increased pressure to cut costs.

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Key Market Trends & Insights

• North America dominated the aerospace 3D printing market with a revenue share of 40.20% in 2023. The growing trend towards digitalization and Industry 4.0 initiatives accelerates the adoption of additive manufacturing in the aerospace sector. Additive manufacturing enables digital design and manufacturing workflows, facilitating rapid iteration, prototyping, and customization of aerospace components.
• Based on component, the hardware segment led the market with the largest revenue share of 63.6% in 2023 and is expected to witness the fastest CAGR during the forecast period. Growing demand for on-site and on-demand manufacturing capabilities is driving market growth. Aerospace operators require quick access to spare parts and replacement components to minimize downtime and ensure the continued operation of their aircraft and spacecraft.
• Based on technology, the selective laser melting (SLM) segment led the market with the largest revenue share of 48.6% in 2023. The demand for innovative design solutions and advanced materials for next-generation aerospace systems is driving the segment's growth. These lightweight and intricately designed components offer significant performance, fuel efficiency, and aerodynamic advantages for aircraft and spacecraft.
• Based on application, the market is further bifurcated into prototyping, tooling, and functional parts. Growing demand to produce functional prototypes that closely mimic the properties of final production parts is driving segment growth. With advancements in materials science and additive manufacturing processes, aerospace-grade materials can now be utilized for prototyping applications, allowing engineers to evaluate mechanical properties, thermal performance, and other critical characteristics of prototypes under real-world conditions.
• Based on materials, the market is further segmented into metal, polymer (plastic), and composite, and is expected to grow at the fastest CAGR during the forecast period. Additive manufacturing techniques eliminate many of the constraints associated with traditional machining processes, such as the need for specialized tooling and extensive material waste.

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Market Size & Forecast

• 3 Market Size: USD 3.13 Billion
• 2030 Projected Market Size: USD 11.38 Billion
• CAGR (2024-2030):20.6%
• North America: Largest market in 2023

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Key Companies & Market Share Insights

Some of the key players operating in the market include Melrose Industries, Lockheed Martin, and Thales.

• Melrose Industries is a British-based industrial conglomerate that operates across various sectors, including automotive, aerospace, energy, and manufacturing. Through its subsidiary GKN Aerospace, Melrose Industries offers additive manufacturing technology in the aerospace industry. By combining GKN Aerospace's aerospace capabilities with Melrose's operational expertise, the company aims to drive innovation and deliver value to its customers in the rapidly evolving aerospace market.
• Thales Group is a multinational company specializing in aerospace, defense, security, and transportation. Thales' expertise in aerospace systems and technology positions the company well to explore the potential of 3D printing in aerospace manufacturing. Thales enhances its capabilities in producing advanced aerospace components with improved efficiency and flexibility by integrating additive manufacturing techniques into its existing product development and manufacturing processes.
• Lockheed Martin Corporation specializes in aerospace, defense, and technology. Lockheed Martin's Aeronautics division is responsible for designing, manufacturing, and servicing advanced military aircraft, including fighter jets and military transport planes. The company used 3D printing to produce the F-35 Lightning II, a fifth-generation multi-role fighter aircraft. Lockheed Martin utilized 3D printing technology to manufacture various components of the F-35, including certain structural parts and engine components. Additionally, the company has partnered with NASA and other organizations to analyze the feasibility of using additive manufacturing to produce spacecraft components, habitats for space exploration, and even rocket engines.

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Key Players

• Spirit AeroSystems
• Thales
• Lockheed Martin
• Melrose Industries
• Booz Allen Hamilton
• Stratasys
• EOS GmbH
• Danaher
• Formlabs
• ExOne

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Conclusion

The aerospace 3D printing market is on a robust growth trajectory, driven by increasing demand for customization, rapid prototyping, and innovative design solutions. Despite challenges posed by the COVID-19 pandemic, the market demonstrates resilience and adaptability, with significant investments in additive manufacturing technologies. As aerospace manufacturers continue to embrace these advancements, the potential for enhanced efficiency, reduced costs, and accelerated innovation in aircraft and spacecraft development remains promising.