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Aerospace Foam Market Research Report Information By Material (PU Foams, PE Foams, Melamine Foams, PMI/Polyimide Foams, and Others), By End Use (Commercial Aircraft, Military Aircraft, and General Aviation), By Application (Aircraft Seats, Aircraft Floor Carpets, Flight Deck Pads, Cabin Walls and Ceilings, Overhead Stow Bins, and Others (Aircraft Prototypes, Galleys and Lavatories)), and By Region (North America, Europe, Asia-Pacific, and Rest Of The World) – Market Forecast Till 2032


ID: MRFR/CnM/10232-HCR | 128 Pages | Author: Anshula Mandaokar| June 2024

Global Aerospace Foam Market Overview


Aerospace Foam Market Size was valued at USD 5.5 Billion in 2022. The Aerospace Foam industry is projected to grow from USD 5.9 Billion in 2023 to USD 9.7 Billion by 2032, exhibiting a compound annual growth rate (CAGR) of 6.50% during the forecast period (2023 - 2032). The recent upsurge in unrest surrounding air travel and the rising desire for lightweight, fuel-efficient aircraft, are the key market drivers enhancing the market growth.


Aerospace Foam Market Overview


Source: Secondary Research, Primary Research, MRFR Database and Analyst Review


Aerospace Foam Market Trends




  • Increasing commotion across air travel in recent years is driving the market growth




Aircraft makers have been forced to reduce aircraft weight and carry greater loads at once as a result of rising fuel expenses. As a result, these producers have begun using aerospace foam in a variety of aircraft applications, including flight deck pads, carbon walls and ceilings, aircraft seats, and aircraft flooring. A further factor driving demand for aircraft across all end uses, including general aviation, commercial aviation, military aircraft, and rotary aircraft, is the recent upsurge in air travel commotion. Because of this, the use of aerospace foam in the manufacture of aircraft has been positively impacted, and this is clearly predicted to continue during the projection period. In 2021, the U.S. accounted for the majority of demand for aerospace foam, and it is projected that this trend will continue during the projection period. The significant growth of the aircraft industry as a result of increasing interstate travel over the past ten years as a result of greater disposable money is the main factor driving the high product demand across the nation.


Due to the rising use of aerospace foam across the external fuel tanks, the U.S. military services have been a prominent industry for driving demand for aerospace foam throughout military aircraft. For instance, the U.S. Air Force (USAF) received four MH-139A test helicopters from aircraft manufacturer Boeing in August 2022, successfully delivering them in order to support four key air force commands, intercontinental ballistic missile defence, and other operating agencies. Due to the COVID-19 pandemic's global spread in 2020, the airline industry experienced a major setback as a result of numerous flight cancellations, airport closures, and the shutdown of manufacturing facilities to stop the virus' spread. This, in turn, had a detrimental effect on the industry's expansion. However, the aircraft industry's activities were resumed, dramatically altering the product demand, due to the rising rate of recovery and the widespread availability of vaccines.


The expansion of commercial aircraft operations over the past few years has been facilitated by declining fuel price fluctuations and rising operational efficiencies. Global aircraft fleet growth has been fueled by rising air travel rates, particularly in emerging nations in Asia-Pacific and South America, as well as rising disposable incomes elsewhere. Over the next 20 years, there will likely be a demand for 44,040 new jets, valued at USD 6.8 trillion, as passenger numbers rise and more people retire. By 2038, the commercial fleet will contain 50,660 aircraft, assuming that all newly developed aircraft and jets continue to be in operation. Thus, driving the Aerospace Foam market revenue.


Aerospace Foam Market Segment Insights


Aerospace Foam Material Insights


The Aerospace Foam Market segmentation, based on material, includes PU foams, PE foams, melamine foams, PMI/polyimide foams, and others. In 2022, the global market was dominated by the PU foams category. The product's broad range of applications is responsible for the high share. PU foams are utilised as insulation for aeroplanes, baggage areas, ceilings, walls, and partitions between class sections and restrooms. Then comes specific high-performance foams like expanded polyethylene (EPE) and special polyethylene (PE) foams. In comparison to conventional foams utilised throughout the aerospace sector, EPE foam offers unmatched dimensional stability and recovery properties. These foams are utilised in the ceilings of aeroplanes to provide the best possible cushioning and reduce repeated impacts.


Aerospace Foam End Use Insights


The Aerospace Foam Market segmentation, based on end use, includes commercial aircraft, military aircraft, and general aviation. In 2022, the global market was dominated by the commercial aircraft End Use sector. Global air travel is expanding, which is accelerating market expansion. Additionally, the expansion of low-cost carriers has increased demand for the commercial aircraft market in areas including South America, the Middle East, and Asia Pacific. These elements are fueling the global market expansion for aerospace foams.


Aerospace Foam Application Insights


The Aerospace Foam Market segmentation, based on application, includes aircraft seats, aircraft floor carpets, flight deck pads, cabin walls and ceilings, overhead stow bins, and others (aircraft prototypes, galleys and lavatories). In 2022, the category for cabin walls and ceilings led the worldwide aerospace foam market. With the fastest growth rate and the largest revenue share during the projected period, the segment is expected to continue to rise. This is due to the aircraft's chassis' extensive use of aerospace foam, particularly PU foam. Since the aircraft's size encloses both people and cargo, it must be very well insulated to prevent any wind exchange between the interior of the aircraft and the outside atmosphere.


Figure 1: Aerospace Foam Market, by Application, 2022 & 2032 (USD Billion)


Aerospace Foam Market, by Application


Source: Secondary Research, Primary Research, MRFR Database and Analyst Review


Aerospace Foam Regional Insights


By region, the study provides the market insights into North America, Europe, Asia-Pacific and Rest of the World. The North America Aerospace Foam Market dominated this market in 2022 (45.80%). Due to an increase in aircraft demand across the nation over the past ten years, the U.S. is a significant contributor to the North America regional market. Major aircraft manufacturers' presence in the U.S. also makes the already intense competition in the local market even more intense. Companies like Lockheed Martin, Boeing, General Electric, Raytheon Technologies Corp., and Safran serve as indicators of the region's intense competition for the manufacture of aircraft. Further, the U.S. Aerospace Foam market held the largest market share, and the Canada Aerospace Foam market was the fastest growing market in the North America region.


Further, the major countries studied in the market report are The US, Canada, German, France, the UK, Italy, Spain, China, Japan, India, Australia, South Korea, and Brazil.


Figure 2: GLOBAL OLED MATERIALS MARKET SHARE BY REGION 2022 (USD Billion)


OLED MATERIALS MARKET SHARE BY REGION 2022 (USD Billion)


Source: Secondary Research, Primary Research, MRFR Database and Analyst Review


Europe Aerospace Foam market accounted for the healthy market share in 2022. Due to the rising number of tourists visiting the continent in recent years, there has been an increase in demand for aircraft. According to the General Aviation Shipment Report 2021, which was released by the General Aviation Manufacturers Association (GAMA), Europe had a 13.6% increase in overall aeroplane shipments in 2021, or roughly 702 aircraft, compared to 618 in 2020. Due to this, product demand has increased throughout the region and is predicted to continue growing at a similar rate during the projected period. Further, the German Aerospace Foam market held the largest market share, and the U.K Aerospace Foam market was the fastest growing market in the European region


The Asia Pacific Aerospace Foam market is expected to register significant growth from 2023 to 2032. The Asia Pacific aerospace foam market is anticipated to grow during the forecast period due to factors such an increase in air travellers and a rise in the demand for stronger, lighter materials to increase aircraft fuel economy in developing nations. Moreover, China’s Aerospace Foam market held the largest market share, and the Indian Aerospace Foam market was the fastest growing market in the Asia-Pacific region.


Aerospace Foam Key Market Players & Competitive Insights


Leading market players are investing heavily in research and development in order to expand their product lines, which will help the Aerospace Foam market, grow even more. Market participants are also undertaking a variety of strategic activities to expand their global footprint, with important market developments including new product launches, contractual agreements, mergers and acquisitions, higher investments, and collaboration with other organizations. To expand and survive in a more competitive and rising market climate, Aerospace Foam industry must offer cost-effective items.


Manufacturing locally to minimize operational costs is one of the key business tactics used by manufacturers in the global Aerospace Foam industry to benefit clients and increase the market sector. In recent years, the Aerospace Foam industry has offered some of the most significant advantages to medicine. Major players in the Aerospace Foam market, including BASF SE, Huntsman Corporation, Armacell, BOYD Corporation, Evonik Industries, Sabic, Rogers Corporation, Zetofoams PLC, General Plastics Manufacturing Company, and ERG Materials, are attempting to increase market demand by investing in research and development operations.


A chemical corporation is BASF SE (BASF). Chemicals, polymers, crop protection products, and performance goods are produced, marketed, and sold by it. Solvents, adhesives, surfactants, fuel additives, electronic chemicals, pigments, paints, food additives, fungicides, and herbicides are among the company's product offerings. Construction, furniture and wood, agricultural, electronics and electrical, paints and coatings, automotive, home care, nutrition, chemicals, and other industries are among the many that the company serves. The first polyethersulfone (PESU)-based particle foam was created by BASF SE in September 2019. Due to the foam's excellent qualities that are needed in aerospace applications, it has been certified for use in aeroplanes.


In Wetteren, Belgium, Recticel Flexible Foams produces polyurethane foam products. The research, production, transformation, and commercialization of primarily semi-finished flexible polyurethane foam products and components for B2B markets are the company's main business activities. The Recticel Engineered Foams business line was created in March 2021 from the merger of Recticel Flexible Foams and FoamPartner. The new organisation will make extensive use of resource and talent synergies to advance excellence, expand its global footprint, and quicken the commercialisation of cutting-edge products for international markets.


Key Companies in the Aerospace Foam market include



  • BASF SE

  • Huntsman Corporation

  • Armacell

  • BOYD Corporation

  • Evonik Industries

  • Sabic

  • Rogers Corporation

  • Zetofoams PLC

  • General Plastics Manufacturing Company

  • ERG Materials


Aerospace Foam Market Segmentation


Aerospace Foam Material Outlook



  • PU Foams

  • PE Foams

  • Melamine Foams

  • PMI/Polyimide Foams

  • Others


Aerospace Foam End Use Outlook



  • Commercial Aircraft

  • Military Aircraft

  • General Aviation


Aerospace Foam Application Outlook



  • Aircraft Seats

  • Aircraft Floor Carpets

  • Flight Deck Pads

  • Cabin Walls and Ceilings

  • Overhead Stow Bins

  • Others (Aircraft Prototypes, Galleys and Lavatories)


Aerospace Foam Regional Outlook



  • North America

    • US

    • Canada



  • Europe

    • Germany

    • France

    • UK

    • Italy

    • Spain

    • Rest of Europe



  • Asia-Pacific

    • China

    • Japan

    • India

    • Australia

    • South Korea

    • Australia

    • Rest of Asia-Pacific



  • Rest of the World

    • Middle East

    • Africa

    • Latin America



Report Attribute/Metric Details
Market Size 2022 USD 5.5 Billion
Market Size 2023 USD 5.9 Billion
Market Size 2032 USD 9.7 Billion
Compound Annual Growth Rate (CAGR) 6.50% (2023-2032)
Base Year 2022
Market Forecast Period 2023-2032
Historical Data 2018- 2022
Market Forecast Units Value (USD Billion)
Report Coverage Revenue Forecast, Market Competitive Landscape, Growth Factors, and Trends
Segments Covered Material, End Use, Application, and Region
Geographies Covered North America, Europe, Asia Pacific, and the Rest of the World
Countries Covered The US, Canada, German, France, UK, Italy, Spain, China, Japan, India, Australia, South Korea, and Brazil
Key Companies Profiled BASF SE, Huntsman Corporation, Armacell, BOYD Corporation, Evonik Industries, Sabic, Rogers Corporation, Zetofoams PLC, General Plastics Manufacturing Company, and ERG Materials
Key Market Opportunities Increasing trends toward bio-based polyurethane foam manufacturing
Key Market Dynamics Increasing commotion across air travel in recent years and the increasing demand for lightweight and fuel-efficient aircraft


Frequently Asked Questions (FAQ) :

The Aerospace Foam Market size was valued at USD 5.5 Billion in 2022.

The global market is projected to grow at a CAGR of 6.50% during the forecast period, 2023-2032.

North America had the largest share in the global market

The key players in the market are BASF SE, Huntsman Corporation, Armacell, BOYD Corporation, Evonik Industries, Sabic, Rogers Corporation, Zetofoams PLC, General Plastics Manufacturing Company, and ERG Materials

The PU Foams Material dominated the market in 2022.

The Commercial Aircraft End Use had the largest share in the global market.

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