Global Smart Composite Layup Machines for Aerospace Market to Expand at 5.8% CAGR Through 2031

Global Smart Composite Layup Machines for Aerospace Market to Expand at 5.8% CAGR Through 2031
Smart Composite Layup Machines for Aerospace

Industry Overview
Smart composite layup machines are advanced automated systems used primarily in the aerospace sector for the high-precision placement of composite materials such as carbon fiber. These machines improve the efficiency, quality, and consistency of manufacturing aircraft structural components including wings, fuselages, and engine reinforcements.

The global market for Smart Composite Layup Machines for Aerospace is set to grow significantly, with a projected increase from USD 1,184 billion in 2024 to USD 1,757 billion by 2031, registering a compound annual growth rate (CAGR) of 5.8% over the forecast period, according to the latest market research report by QYResearch.

Key Trends in 2025
1. Accelerated Adoption of AFP and ATL Technologies
Automated Fiber Placement (AFP) and Automated Tape Laying (ATL) technologies are seeing increased uptake in 2025 due to rising demand for precision and efficiency in aerospace composite manufacturing. Market research indicates that the global AFP and ATL machine market is projected to reach approximately USD 710.1 million by 2032, growing at a CAGR of 9.0%.

These technologies enable high-speed, high-accuracy layup of carbon fiber and other composite materials, minimizing waste and labor while enhancing part consistency and structural performance-critical in aircraft wings, fuselages, and nacelles.

2. Emergence of Robotic and Multi-Functional Composite Layup Systems
2025 has seen major aerospace players integrate robotic layup systems for parts with complex geometries. These systems reduce manual intervention and improve process repeatability. Companies like MTorres and Electroimpact have developed robotic arms capable of dynamic path adjustments during layup, allowing for higher degrees of customization and reduced production lead time.

3. Integration of AI-Based Controls and Smart Monitoring
Artificial Intelligence (AI) is playing a growing role in enhancing real-time quality control. Modern smart layup machines now incorporate vision systems and edge computing units to detect fiber misalignments, voids, or delamination on the fly. These systems automatically alert operators or halt production when anomalies exceed tolerances.

Additionally, AI analytics platforms aggregate production data across multiple facilities to forecast maintenance, predict material usage, and improve overall efficiency by 12-18% according to AddComposites.

4. Sustainability and Thermoplastic Integration
Sustainability continues to be a driving factor in 2025. Thermoplastic composites, favored for their recyclability and fast forming, are gaining ground over thermosets. Equipment makers are adapting layup heads and preheating technologies to handle newer resins. Airborne and SABIC are spearheading projects in this direction, supported by the European Union's "Green Aviation" initiative.

5. Global Expansion and Localization
Market penetration is expanding in Asia-Pacific and the Middle East. Countries like India, Turkey, and the UAE are investing in localized aerospace supply chains, leading to increased procurement of smart layup systems. This is reinforced by government-driven modernization programs and public-private partnerships.

Together, these trends are redefining how composite structures are manufactured in aerospace, shifting from labor-intensive processes to data-driven, highly automated, and globally scalable solutions.

Latest Company Developments
Fives Group has introduced its new generation of Forest-Liné TapeLay and ACES® software, significantly boosting automation and throughput in composite layup operations.

Electroimpact and MTorres continue to dominate with high-performance AFP machines tailored for aerospace giants, focusing on lightweighting and manufacturing flexibility.

Market Segmentation
By Type:
· Automated Tape Laying Machines

· Automated Fiber Placement Machines

· Robotic Composite Layup Systems

· Multi-functional Composite Layup Units

· Others

By Application:
· Aircraft Wing Manufacturing

· Fuselage Structure Manufacturing

· Engine Component Reinforcement

· Spacecraft Composite Structures

· Others

Leading Market Players
The report identifies major manufacturers including:

· Electroimpact

· MTorres

· Fives Group

· Autonational

· Ingersoll Machine Tools

· Broetje-Automation

· Airborne

· GFM GmbH

· AFPT GmbH

· Coriolis Composites

Regional Insights
North America and Asia-Pacific are poised to witness robust growth. While North America remains the largest market, Asia-Pacific shows the highest potential due to increased aerospace investments and manufacturing capabilities in countries like China and India.

Five Key Machines from Leading Manufacturers

Electroimpact AFP 4.0 Series

· Delivers 4-8× higher throughput over legacy systems by reducing manual touch points and speeding layup cycles, ideal for large wing spars and fuselage sections.

· Modular AFP heads support 1⁄4′′ and 1⁄2′′ tows, thermoset, thermoplastic, dry fiber, and realtime inspection systems

• MTorres TORRESFIBERLAYUP AFP Robot

· Offers 60-100 m/min placement rates, with multiaxis robotic arms capable of dynamic path correction.

· Designed for complex contours like fuselage panels and wing spars, supporting high productivity in aerospace production.

• Fives ForestLiné ATLAS/ACCESS ATL System

· A dualphase tapelaying setup that precuts and lays tapes up to 6.5 m wide with positioning accuracy of 0.5 mm and speeds of 60 m/min, offering 2-3× faster performance than standard systems.

· Equipped with ACES® software suite enabling full CAD/CAM, ultrasonic cutting, and inprocess inspection control.

• Fives Cincinnati SuperCharger ATL Machine

· Market-leading speed: 60% faster than older ATL machines, with onthefly ultrasonic cutting and fouraxis control optimized for complex flightgrade laminates .

· Excels in laying netshape tapes on curved or contour surfaces commonly found in aircraft skins.

• Airborne Automated Ply Placement System

· Fully automated system integrating ply cutting, placement, inspection, and storage; demonstrated capacity for thermoplastic aerospacegrade composite production.

· Recognized by Airbus for thermoplastic fuselage demonstrator programs, supporting sustainable manufacturing shifts

Challenges and Outlook
The industry must navigate challenges including trade uncertainties such as the 2025 U.S. tariff policies, which may impact global supply chains. However, the push towards automation, intelligent manufacturing, and lightweight aircraft structures ensures long-term growth opportunities.

This report serves as a vital resource for OEMs, machine manufacturers, and stakeholders seeking actionable insights and strategic direction in the evolving smart aerospace composite manufacturing space.

Related Reports:

Global Smart Composite Layup Machines for Aerospace Market Research Report 2025

https://www.qyresearch.com/reports/4743502/smart-composite-layup-machines-for-aerospace

Smart Composite Layup Machines for Aerospace - Global Market Share and Ranking, Overall Sales and Demand Forecast 2025-2031

https://www.qyresearch.com/reports/4743501/smart-composite-layup-machines-for-aerospace

Global Smart Composite Layup Machines for Aerospace Sales Market Report, Competitive Analysis and Regional Opportunities 2025-2031

https://www.qyresearch.com/reports/4743500/smart-composite-layup-machines-for-aerospace

Global Smart Composite Layup Machines for Aerospace Market Insights, Forecast to 2031

https://www.qyresearch.com/reports/4743499/smart-composite-layup-machines-for-aerospace

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