Aerospace & Defense Process Materials Market to Reach USD 589 Million by 2030

The Aerospace & Defense Process Materials Market is witnessing steady expansion as aircraft manufacturers increase composite content, raise production rates, and adopt advanced composite manufacturing processes across commercial and military aircraft programs.

According to Stratview Research, the global aerospace & defense process materials market was valued at USD 410 million in 2024, compared with USD 361 million in 2023, representing 13.6% year-over-year growth. The market is expected to reach USD 469 million in 2025, reflecting 14.4% annual growth, and is projected to reach USD 589 million by 2030, registering a CAGR of 4.7% during 2025-2030.

The market is also expected to generate a cumulative sales opportunity of USD 3,189 million during 2025-2030, highlighting attractive opportunities for process-material manufacturers, composite suppliers, aircraft OEMs, Tier suppliers, and advanced-material distributors.

Report Highlights

• Market Size (2023): USD 361 Million
• Market Size (2024): USD 410 Million
• YoY Growth in 2024: 13.6%
• Market Size (2025): USD 469 Million
• YoY Growth in 2025: 14.4%
• Forecast Market Size (2030): USD 589 Million
• Forecast Period: 2025-2030
• CAGR: 4.7%
• Cumulative Sales Opportunity: USD 3,189 Million
• Largest Region: North America
• North America Market Share (2024): More than 40%
• Largest & Fastest-Growing Aircraft Type: Commercial Aircraft
• Largest Product Type: Vacuum Bagging Film
• Fastest-Growing Product Type: Release Film
• Largest Process Type: Prepreg Layup
• Top 10 Countries' Market Share: More than 80%
• Top 10 Companies' Market Share: 50%-70%

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Composite Aircraft Production Drives Process Material Demand

Process materials play an important role in manufacturing aerospace composite structures.

They help remove excess air and resin from laminates, improve the fiber-to-resin ratio, and support production of high-performance composite components.

They can also contribute to reducing volatile organic compound emissions during manufacturing.

Major process materials include

• Vacuum bagging films
• Release films
• Peel plies
• Breathers
• Bleeders
• Other auxiliary materials

Demand is closely linked to composite consumption across next-generation aircraft.

Aircraft programs such as the Boeing 737 MAX, Boeing 787, Boeing 777X, Airbus A350 XWB, Airbus A220, and Airbus A320neo use significant levels of composite materials, supporting recurring demand for processing consumables.

Aerospace & Defense Process Materials Market by Aircraft Type

By aircraft type, the market is segmented into:

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

Commercial aircraft are expected to remain both the largest and fastest-growing aircraft segment during the forecast period.

The segment is expected to maintain a market share of slightly below 70%.

Its leadership is supported by production increases across key Boeing and Airbus aircraft programs.

Higher production rates directly raise requirements for composite parts and the consumable process materials used to manufacture them.

Large aircraft order backlogs also provide long-term visibility for suppliers serving composite aerostructure programs.

The military aircraft segment also represents a meaningful demand base.

Military aviation has historically been an important adopter of composite technologies, and rising defense expenditure is creating additional opportunities for process-material suppliers.

Vacuum Bagging Films Lead by Product Type

By product type, the market is segmented into:

• Vacuum Bagging Film
• Release Film
• Peel Ply
• Breathers & Bleeders
• Other Process Materials

Vacuum bagging film is expected to remain the dominant product type throughout the forecast period.

Vacuum bagging films are essential in composite manufacturing because they help create a closed processing environment.

They support:

• Improved resin flow
• Reduced air entrapment
• Controlled consolidation
• Improved laminate quality
• Consistent composite processing

Aerospace applications also require bagging films capable of operating under elevated temperatures and pressures.

These performance requirements make high-quality vacuum bagging films critical to advanced aircraft composite manufacturing.

Release Films Expected to Grow Fastest

The release film is projected to record the fastest growth.

Release films are used where easy separation between materials is required during composite manufacturing.

Their versatility and functional performance support adoption across multiple composite-processing applications.

As aircraft manufacturers and aerostructure suppliers increase production of composite parts, release-film consumption is expected to grow alongside wider use of prepregs and resin-based manufacturing processes.

Prepreg Layup Dominates by Process Type

By process type, the market is segmented into:

• Prepreg Layup
• Resin Infusion
• Other Processes

Prepreg layup is expected to remain the largest process segment.

Prepreg materials are widely used in modern aircraft because they provide:

• Consistent fiber-resin ratios
• Reliable material quality
• Ease of use
• High structural performance

These advantages make prepreg processing important for manufacturing high-performance aerospace composite components.

The strong penetration of prepreg-based composites across modern aircraft platforms consequently creates significant demand for vacuum bagging films, release films, peel plies, breathers, and bleeders.

Resin Infusion Gains Momentum

Resin infusion is gradually gaining momentum, particularly in engine-related applications.

The process offers an alternative approach to composite manufacturing and creates demand for process materials compatible with infusion-based production.

As aerospace manufacturers explore different manufacturing routes to improve production efficiency and component economics, resin infusion could provide incremental growth opportunities.

Increasing Composite Content Supports Long-Term Demand

One of the strongest market drivers is the increasing amount of composite material used per aircraft.

Modern aerospace structures increasingly incorporate composites because of their lightweight characteristics and strong mechanical performance.

Higher composite content translates directly into greater consumption of process materials during component manufacturing.

Advancements in composite-processing technology also support greater use of:

• Automated manufacturing
• Higher-temperature processing
• More complex composite structures
• Improved production repeatability

This makes process materials an essential consumable category within the broader aerospace composites ecosystem.

North America Leads the Market

North America is expected to remain the largest regional aerospace & defense process materials market.

The region accounted for more than 40% of global demand in 2024.

Its leadership is supported by a mature advanced-composites ecosystem that includes:

• Aircraft OEMs
• Component manufacturers
• Process-material suppliers
• Raw-material companies

The region has historically been at the forefront of advanced aerospace composite manufacturing, supporting continued demand for high-performance process consumables.

Asia-Pacific Emerges as a New Growth Center

Asia-Pacific is becoming increasingly important as aerospace and defense manufacturing expands across the region.

Growth is being supported by increasing aircraft production, domestic aerospace programs, and localization of composite manufacturing.

China, in particular, is placing greater emphasis on localizing manufacturing processes and reducing dependence on imported materials.

This trend is expected to strengthen the presence of regional process-material manufacturers and create additional competition over the forecast period.

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Market Challenges

The market faces several important barriers.

High Manufacturing Costs

Aerospace process materials must perform reliably under demanding temperatures, pressures, and manufacturing environments.

Producing such materials requires specialized polymers, coatings, processing equipment, and quality-control systems, contributing to relatively high manufacturing costs.

Stringent Qualification Requirements

Aerospace suppliers must undergo lengthy qualification processes before materials can be introduced into aircraft manufacturing programs.

These requirements can increase development costs and slow supplier entry.

Skilled Labor Constraints

Advanced composite manufacturing requires trained personnel capable of handling process materials, prepregs, bagging systems, and increasingly complex production methods.

A shortage of experienced composite-manufacturing professionals can therefore constrain industry expansion.

Competitive Landscape

The Aerospace & Defense Process Materials Market is consolidated, although regional suppliers, particularly in Asia, are increasing their presence.

The top 10 companies accounted for approximately 50%-70% of global market sales in 2024.

Key market participants include:

• Airtech Advanced Materials Group
• Aerovac Composites One
• Flextech S.R.L.
• Diatex SAS
• Precision Fabrics Group
• METYX Composites
• Kejian Polymer Materials Co., Ltd.
• Shanghai Leadgo-Tech Co., Ltd.
• Zhejiang Hengyida Composite Materials Co., Ltd.
• Zhejiang Youwei New Materials Co., Ltd.

Competitive factors include pricing, service offerings, product performance, and regional presence.

Industry consolidation has also influenced the competitive landscape. Composites One acquired Solvay's process-materials business in 2021 and subsequently rebranded the operation as Aerovac.

Conclusion

The Aerospace & Defense Process Materials Market is positioned for steady growth as composite content increases across commercial and military aircraft and production rates recover across major aircraft programs.

The market is expected to grow from USD 469 million in 2025 to USD 589 million by 2030, registering a 4.7% CAGR and creating a USD 3.19 billion cumulative sales opportunity.

Commercial aircraft will remain the largest and fastest-growing aircraft segment.

Vacuum bagging films will continue to dominate by product type, while release films record the fastest growth.

Prepreg layup will remain the leading manufacturing process, while resin infusion gradually gains momentum.

North America will maintain regional leadership, while Asia-Pacific becomes increasingly important as aerospace manufacturing and localization expand.

As aircraft manufacturers continue increasing composite content and improving production efficiency, process materials will remain an essential part of the global aerospace and defense composites manufacturing ecosystem.

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