Aerospace Foam Market Size, Share, Industry, Forecast and outlook (2024-2031)

Global Aerospace Foam Market is segmented By Applications (Insulation panels, Cabin Walls and Ceilings, Class Dividers, Overhead Stow Bins, Composite Cores​​​​​​​, Tooling Board, Aircraft Prototypes, Others​​​​​​​), Material (Polyurethane, Polyethylene, Melamine, Metal, Polyimide, Silicones, PET, Others), By End Users (Commercial, General Aviation, Military Aircraft), By Capability (CNC Machining, Pattern making, Tooling, Assembly, Painting, Adhesive bonding, Pre-preg and potting processes, Resin-infusion processes), By Region (North America, Europe, South America, Asia Pacific, Middle East, and Africa) – Share, Size, Outlook, and Opportunity Analysis, 2023-2030

Aerospace Foam Market Overview

[260 pages] Report analyses the Global Aerospace Foam Market shares, recent trends, and market player analysis. The Market is estimated to reach at CAGR of 10.8% during the forecast period 2023 - 2030. North America region holds the largest market share for the aerospace foam market globally. The Competitive rivalry intensifies with Evonik Industrie, Aero foam Industries and BASF SE.

Aerospace foams are low-density and cellular structured materials used for vibration dampeners, insulation, sealing, sound blocking, gasketing and cushioning. The foams are widely used in various components such as flight deck pads, passenger cabin walls, ceilings, storage containers, section dividers and lavatory elements due to their excellent rigidness, tensile strength, durable and lightweight. The aerospace foams are made up of various materials including polyethylene, melamine foams, metal foams, polyimide foams, silicones foams, pet foams and others.

Aerospace Foam Market Scope

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Aerospace Foam Market Dynamics

The global aerospace foam market growth is driven by demand for lightweight & advanced products, growing demand for fire-resistant foams and increasing investments in military aircraft.

Demand for lightweight & advanced products 

The demand for decreasing the aircraft's weight and developing new polymers are significant factors for boosting the market's growth. According to a recent study, lightweight composite metal foams can absorb energy from impacts and block rays and radiation for the aerospace industry.

The market has observed technical advancements to develop polymer foams with more remarkable performance in expanding aerospace industry. There are several launches by the leading players to satisfy the aerospace industry's need like in 2020, Zotefoams has expanded its high-performance product line with the introduction of polyvinylidene fluoride foam, ZOTEK F X.R., the product offers cross-linked foam available in densities, flexibility and semi-rigid. In 2018, Evonik Industries launched a new foam ROHACRYL, the product offers thermal stability, lightweight, environmentally friendly.

The companies have been conducting various research and developments globally in search of better products like in 2019, Toray Advanced Composites has signed along with United Kingdom’s National Composites Centre (NCC) signed a Tier 1 membership. The two companies will collaborate with the significant composites innovation programs within both the aerospace and automotive sectors. As part of the project, companies will be working on the Wing of Tomorrow project, Airbus’ largest research and technology program, developing a composite wing manufacturing for a next-generation single-aisle aircraft.

Governmental standards associated with the use of foam

The aerospace foam market is impacted by stringent governmental standards such as NEHSAP and ASTM on the use of PU foams. The requirements for aerospace foam vary as compared to conventional foams. For example, aerospace foams should be flame retardant, produce low smoke & heat release and satisfy standards set for aerospace applications for numerous aerospace standards. 

Moreover, aerospace foams are costlier and need extra processing to fulfill the criteria for aerospace standards. Also, the recycling of PU is complicated because hazardous chemicals are some of the major factors responsible for restraining market growth. Nevertheless, the advancement in technologies and renewable feedstock for green PU foams offer lucrative growth opportunities.

COVID-19 Impact Analysis on Aerospace Foam Market

Due to the pandemic, stakeholders across the aerospace foam industry have seen a notable impact as all the production work, factories and other activities were closed. The production was hindered by halts and supply chain disruption globally. After the pandemic, the governments still imposed various restrictions, such as working with half the workforce and fewer operating hours hindering the production cycle of the market. The losses incorporated with the cancellation of all the flights globally resulting in less demand for the aerospace foam industries. According to the International Civil Aviation Organization, seating capacity in aircrafts fell by around 50% year accounting for 4.5 billion passengers in 2019; the number is further reduced to 1.8 billion passengers taking flights in 2020. That adds up to a financial loss of around US$370 billion to the industry of around with airports and air navigation services losing US$115 billion and US$13 billion respectively.

Aerospace Foam Market Segmentation Analysis

By material, the aerospace foam market is broadly classified into polyurethane (PU), polyethylene (PE), melamine, metal and others.

The polyurethane foam market is expected to grow at the fastest CAGR during the forecast period (2021-2028)

The polyurethane foam is expected to hold the largest market for the aerospace foam market because of its wide range of applications in the aerospace industry compared to any other industry. Throughout the process, aircraft are exposed to numerous weather challenges. The exterior of the aircraft is subjected to rapid temperature changes in temperature. PU foams offer advanced temperature and insulating properties for protecting the aircraft from extreme temperature fluctuations. In addition, The density of the foam prevents air leakage into the aircraft, preserving cabin pressure. PU foams offer a solid sound barrier for protection against the high decibel levels of aircraft engines, high compressive strength allows strength for different needs and contributes to wide usage in the aerospace industry. In 2017, General Plastics launched new polyurethane dielectric material with high thermal processing properties for offering in 3-, 4- and 6-pcf blocks.

The emphasis for polyurethane foam is due to its adaptability to the atmosphere, unlike others. The PU foam is designed in a wide variety of forms such as flame retardant, making it possible to show its impressive range of properties. For instance, NASA developed unique PU Foam to insulate and protect the external fuel tank of the space shuttle. The foam layer on the external fuel tank keeps 395,000 gallons of liquid hydrogen at a very cool -423 degrees Fahrenheit.

Global Aerospace Foam Market Geographical Share

North America region holds the largest market for the global Aerospace Foam globally

North America region holds the largest market share for the aerospace foam market globally and is expected to continue its dominance in the forecast period. The presence of leading countries such as the US, Canada and Mexico are the significant consumers of aerospace foams due to the highest aviation industry. For instance, U.S accounted the highest market share for aviation passengers with over 800 million and 13000 airports. The region seeks the demand for lightweight aerospace parts and materials complying with the regulations.

The region has emerged with the launching of new products and partnerships from the top market players in the aerospace foam market. In 2020, Greiner Aerospace acquired the Eurofoam Group from Belgian Recticel S.A. to ensure the highest quality and innovative foam products for aircraft seat cushions, covers and other segments. In 2019, Aerofoam Industries signed an agreement with Delta One Airlines to provide every aircraft seat cushion and cover on this plane manufactured in Southern California at an Aerofoam facility. Also, the company assisted the Mitsubishi Aircraft Corporation with redeveloping the dress covers, cushions, and plastic components for the SpiceJet 100 cabin mockup in anticipation of the 2019 Paris Air Show.

Aerospace Foam Market Companies and Competitive Landscape

The aerospace foam market is highly competitive and consolidated with the presence of global companies, contributing to the major share in the market growth. In addition, some of the key players contributing to the growth of the market are Aerofoam Industries, Huntsman Corporation, Evonik Industries, Boyd Corporation, Rogers Corporation, General Plastics Manufacturing Company, Sabic Innovative Plastics, ERG Materials, BASF SE, Zetofoams Plc and others. The major players are adopting various new strategies to dominate the market, such as launching new products, acquisitions and collaborations, contributing to the growth of the aerospace foam market globally.

General Plastics Manufacturing Company

Overview: General Plastics manufacturing company is engaged in providing high-quality, high-performance composite assemblies and finished custom parts meeting the stringent requirements of engineers and design teams in numerous industries for 80 years. The company has been manufacturing its products based on ISO 9001:2015/AS9100D, NQA-1, Mil-I-45208A, Boeing Company D6-82473, ITAR-Compliant, Nadcap AC7130 Rev C., Nadcap AC7130/1 Rev A certifications.

Product Portfolio: The Company has various manufacturing wide range of rigid foams, flexible foam (sheet stock) and flexible foam (parts program).

Key Development: In 2018, General Plastics launched the new LAST-A-FOAM RF-2200 dielectric foam series, explicitly developed for radomes and other radio-frequency applications at JEC World.

The global aerospace foam market report would provide access to an approx: 69 market data table, 77 figures and 260 pages.