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US Carbon Composites Market

ID: MRFR/CnM/14929-HCR
111 Pages
Chitranshi Jaiswal
October 2025

US Carbon Composites Market Research Report By Matrix (Hybrid, Metal, Ceramic, Carbon, Polymer) and By Process (Prepeg Layup Process, Pultrusion and Winding, Wet Lamination and Infusion Process, Press and Injection Processes, Other Processes) - Forecast to 2035.

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US Carbon Composites Market Summary

As per Market Research Future analysis, the US carbon composites market Size was estimated at 4500.0 USD Million in 2024. The US carbon composites market is projected to grow from 4829.85 USD Million in 2025 to 9800.0 USD Million by 2035, exhibiting a compound annual growth rate (CAGR) of 7.3% during the forecast period 2025 - 2035

Key Market Trends & Highlights

The US carbon composites market is experiencing robust growth driven by technological advancements and increasing applications across various sectors.

  • The aerospace segment remains the largest, reflecting a strong demand for lightweight materials in aircraft manufacturing.
  • Automotive applications are the fastest-growing segment, as manufacturers seek to enhance fuel efficiency and performance.
  • There is a notable focus on sustainability and recycling, aligning with global environmental goals and consumer preferences.
  • Technological advancements in manufacturing and regulatory support for lightweight materials are key drivers propelling market expansion.

Market Size & Forecast

2024 Market Size 4500.0 (USD Million)
2035 Market Size 9800.0 (USD Million)
CAGR (2025 - 2035) 7.33%

Major Players

Toray Industries (JP), Hexcel Corporation (US), SGL Carbon (DE), Mitsubishi Chemical (JP), Teijin Limited (JP), Solvay S.A. (BE), Cytec Industries (US), Zoltek Companies (US), Axiom Materials (US)

US Carbon Composites Market Trends

The carbon composites market is currently experiencing a notable transformation, driven by advancements in technology and increasing demand across various sectors. Industries such as aerospace, automotive, and construction are increasingly adopting these materials due to their lightweight properties and high strength-to-weight ratios. This shift is further supported by a growing emphasis on sustainability, as carbon composites offer the potential for reduced energy consumption and lower emissions during production and use. As manufacturers continue to innovate, the market is likely to see enhanced performance characteristics, making these materials even more appealing to end-users. In addition, the regulatory landscape is evolving, with stricter environmental standards prompting companies to seek out more sustainable materials. This trend is expected to accelerate the adoption of carbon composites, as they align with the goals of reducing carbon footprints and improving energy efficiency. Furthermore, ongoing research and development efforts are anticipated to yield new applications and improve the recyclability of these materials, thereby expanding their market reach. Overall, the carbon composites market appears poised for growth, driven by technological advancements and a shift towards more sustainable practices.

Increased Adoption in Aerospace

The aerospace sector is increasingly utilizing carbon composites due to their lightweight nature, which contributes to fuel efficiency and performance. This trend is likely to continue as manufacturers seek to enhance aircraft design and reduce operational costs.

Growth in Automotive Applications

The automotive industry is progressively integrating carbon composites into vehicle manufacturing. This shift is driven by the need for lighter materials that improve fuel efficiency and reduce emissions, aligning with regulatory pressures and consumer preferences.

Focus on Sustainability and Recycling

There is a growing emphasis on sustainability within the carbon composites market. Efforts to improve the recyclability of these materials are gaining traction, as companies aim to meet environmental standards and reduce waste in production processes.

Market Segment Insights

By Matrix: Carbon (Largest) vs. Polymer (Fastest-Growing)

In the US carbon composites market, the segment distribution reveals a robust standing for carbon composites, which hold the largest market share due to their superior strength-to-weight ratio and durability. Meanwhile, hybrid composites are also significant, offering distinctive advantages for diverse applications, although they account for a smaller market share compared to the leading carbon segment. Ceramic and metal composites follow, appealing to niche markets with specific performance requirements. Growth trends in this segment are being actively driven by advancements in technology and increased demand for high-performance materials in industries such as aerospace, automotive, and construction. Carbon composites are experiencing sustained demand due to their lightweight features that enhance fuel efficiency and sustainability. Polymer composites, on the other hand, are emerging faster, gaining traction from the growing need for innovative materials that deliver both cost-effectiveness and high performance in various applications.

Carbon (Dominant) vs. Polymer (Emerging)

The carbon segment is dominant in the US carbon composites market, celebrated for its remarkable mechanical properties and high thermal resistance, making it crucial for industries requiring lightweight and high-strength materials. Its performance characteristics position it as the preferred choice for aerospace and automotive applications. In contrast, polymer composites are emerging rapidly, appealing to manufacturers seeking versatile and cost-effective solutions. This segment benefits from continuous innovations, enhancing properties such as flexibility, chemical resistance, and ease of processing. The favorable cost-performance balance of polymer composites, combined with increasing environmental awareness, is fostering their growth as an alternative to traditional materials.

By Process: Prepreg Layup Process (Largest) vs. Pultrusion and Winding (Fastest-Growing)

The US carbon composites market exhibits a diverse range of processes, with the Prepreg Layup Process commanding the largest market share. This technique is recognized for its efficiency and the high-quality end products it generates, allowing manufacturers to cater to various industries such as aerospace, automotive, and sports equipment. Pultrusion and Winding follows, where its unique ability to fabricate continuous lengths of composite materials significantly contributes to its increasing adoption. Growth trends in the market are primarily driven by advancements in manufacturing technology and rising demand for lightweight, high-strength materials across various sectors. The Prepreg Layup Process remains a staple due to its strong market presence, though Pultrusion and Winding is rapidly gaining traction among manufacturers seeking innovative solutions. Increased investment in R&D is also expected to propel these processes forward, allowing them to meet evolving consumer demands more effectively.

Prepreg Layup Process (Dominant) vs. Pultrusion and Winding (Emerging)

The Prepreg Layup Process is a dominant force in the US carbon composites market, primarily due to its ability to deliver products with superior mechanical properties and reduced cycle times. This method employs pre-impregnated fibers, which enhance consistency and quality. Industry leaders favor this technique for its adaptability in various applications, from aerospace components to high-performance sporting goods. Conversely, Pultrusion and Winding is emerging as an innovative process, ideal for producing complex shapes with continuous lengths. This method's capacity for high-volume production and efficiency makes it increasingly attractive to manufacturers looking to optimize costs while meeting high-performance standards. Together, these segments underscore the dynamic nature of the carbon composites landscape.

By Application: Aerospace and Defense (Largest) vs. Automotive (Fastest-Growing)

The US carbon composites market exhibits a diverse market share distribution among various application segments, with the aerospace and defense sector holding the largest share. This segment's growth is driven by the increasing demand for lightweight, high-performance materials in aircraft manufacturing and defense applications. Following closely is the automotive sector, which has seen a burgeoning interest in carbon composites as manufacturers strive for fuel efficiency and improved vehicle performance. Growth trends indicate a promising future for the automotive segment, which is evolving rapidly due to advancements in electric vehicle technology and stricter emission regulations. Additionally, sustainability trends are influencing the adoption of carbon composites across applications. Other segments like wind turbines and civil engineering, while significant, have slower growth rates compared to aerospace and automotive applications due to market maturity and regulatory challenges.

Aerospace and Defense: Dominant vs. Automotive: Emerging

The aerospace and defense sector remains dominant in the application of carbon composites, leveraging these materials' superior strength-to-weight ratios to advance structural integrity and performance. This sector's focus is primarily on delivering high-value performance in aircraft and military applications, resulting in a robust market position. Conversely, the automotive industry is emerging as a major player, driven by innovation in lightweight design and sustainability goals. The shift toward electric vehicles and energy-efficient systems is propelling demand for carbon composites, making it a rapidly growing segment. The competition between these segments highlights the transformative potential of carbon composites in enhancing performance and fuel efficiency across various applications.

Get more detailed insights about US Carbon Composites Market

Key Players and Competitive Insights

The carbon composites market is currently characterized by a dynamic competitive landscape, driven by increasing demand across various sectors such as aerospace, automotive, and renewable energy. Key players are actively pursuing strategies that emphasize innovation, sustainability, and technological advancement. For instance, Toray Industries (Japan) has positioned itself as a leader in high-performance materials, focusing on R&D to enhance product capabilities. Similarly, Hexcel Corporation (US) is leveraging its expertise in composite materials to expand its footprint in the aerospace sector, while SGL Carbon (Germany) is concentrating on sustainable production methods to meet the growing demand for eco-friendly solutions. These strategic orientations collectively shape a competitive environment that is increasingly focused on technological differentiation and sustainability.

In terms of business tactics, companies are localizing manufacturing to reduce lead times and optimize supply chains. This approach is particularly relevant in a moderately fragmented market where collaboration among key players can enhance operational efficiency. The competitive structure is influenced by the presence of both established firms and emerging players, creating a landscape where innovation and strategic partnerships are paramount for success.

In October 2025, Hexcel Corporation (US) announced a partnership with a leading aerospace manufacturer to develop next-generation composite materials aimed at reducing aircraft weight and improving fuel efficiency. This collaboration underscores Hexcel's commitment to innovation and positions it favorably in a market that increasingly prioritizes sustainability. The strategic importance of this partnership lies in its potential to enhance product offerings and strengthen Hexcel's market position in the aerospace sector.

In September 2025, SGL Carbon (Germany) unveiled a new production facility in the US dedicated to the manufacturing of carbon fiber composites. This facility is expected to significantly increase production capacity and reduce costs, thereby enhancing SGL's competitive edge. The establishment of this facility reflects a strategic move to localize production and respond to the growing demand for carbon composites in North America, indicating a proactive approach to market dynamics.

In August 2025, Zoltek Companies (US) launched a new line of low-cost carbon fiber products aimed at the automotive sector. This initiative is indicative of Zoltek's strategy to penetrate new markets by offering cost-effective solutions without compromising on quality. The introduction of this product line may attract a broader customer base and enhance Zoltek's competitive positioning in a price-sensitive market.

As of November 2025, the competitive trends in the carbon composites market are increasingly defined by digitalization, sustainability, and the integration of advanced technologies such as AI. Strategic alliances are becoming more prevalent, as companies recognize the need to collaborate to enhance innovation and operational efficiency. Looking ahead, competitive differentiation is likely to evolve from traditional price-based competition to a focus on technological innovation, supply chain reliability, and sustainable practices. This shift suggests that companies that prioritize R&D and sustainable solutions will be better positioned to thrive in the evolving market landscape.

Key Companies in the US Carbon Composites Market market include

Industry Developments

The US Carbon Composites Market has experienced notable developments recently. Companies like Kordsa Teknik Tekstil A.S. and Toray Industries have been investing in advanced manufacturing processes to enhance the structural integrity of carbon composites, reflecting ongoing innovations in the industry. In August 2023, Hexcel announced the expansion of its production capabilities in the US to meet rising demand from aerospace applications, particularly from major clients like Boeing. Additionally, Solvay has reported advancements in sustainable carbon fiber technologies, aiming to reduce the environmental footprint of composite materials.

Mergers and acquisitions have also been significant, with Northrop Grumman acquiring Zoltek Companies in July 2023 to strengthen its position in carbon fiber production, while Cytec Solvay Group integrated advanced composite solutions to enhance its service offerings. The market has shown growth potential, with a valuation increase driven by robust demand from aerospace, automotive, and industrial sectors, which indicates a thriving landscape for key players like General Electric and Mitsubishi Chemical Corporation. The dynamics in the market remain positive, spurred by investments in Research and Development and strategic collaborations among these core companies.

Future Outlook

US Carbon Composites Market Future Outlook

The carbon composites market is projected to grow at a 7.33% CAGR from 2024 to 2035, driven by advancements in aerospace, automotive, and renewable energy sectors.

New opportunities lie in:

  • Development of lightweight carbon composite materials for electric vehicles
  • Expansion of carbon composite applications in wind turbine manufacturing
  • Investment in recycling technologies for carbon composites to enhance sustainability

By 2035, the carbon composites market is expected to achieve substantial growth and innovation.

Market Segmentation

US Carbon Composites Market Matrix Outlook

  • Hybrid
  • Metal
  • Ceramic
  • Carbon
  • Polymer

US Carbon Composites Market Process Outlook

  • Prepreg Layup Process
  • Pultrusion and Winding
  • Wet Lamination and Infusion Process
  • Press and Injection Processes
  • Other Processes

US Carbon Composites Market Application Outlook

  • Aerospace and Defense
  • Automotive
  • Wind Turbines
  • Sport and Leisure
  • Civil Engineering
  • Marine Applications
  • Other Applications

Report Scope

MARKET SIZE 20244500.0(USD Million)
MARKET SIZE 20254829.85(USD Million)
MARKET SIZE 20359800.0(USD Million)
COMPOUND ANNUAL GROWTH RATE (CAGR)7.33% (2024 - 2035)
REPORT COVERAGERevenue Forecast, Competitive Landscape, Growth Factors, and Trends
BASE YEAR2024
Market Forecast Period2025 - 2035
Historical Data2019 - 2024
Market Forecast UnitsUSD Million
Key Companies Profiled["Toray Industries (JP)", "Hexcel Corporation (US)", "SGL Carbon (DE)", "Mitsubishi Chemical (JP)", "Teijin Limited (JP)", "Solvay S.A. (BE)", "Cytec Industries (US)", "Zoltek Companies (US)", "Axiom Materials (US)"]
Segments CoveredMatrix, Process, Application
Key Market OpportunitiesGrowing demand for lightweight materials in automotive and aerospace sectors drives innovation in the carbon composites market.
Key Market DynamicsRising demand for lightweight materials drives innovation and competition in the carbon composites market.
Countries CoveredUS

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FAQs

What is the expected market size of the US Carbon Composites Market in 2024?

The US Carbon Composites Market is expected to be valued at 4.5 USD Billion in 2024.

What is the projected market size of the US Carbon Composites Market by 2035?

By 2035, the US Carbon Composites Market is projected to reach a value of 11.0 USD Billion.

What is the compound annual growth rate (CAGR) for the US Carbon Composites Market from 2025 to 2035?

The market is expected to grow at a CAGR of 8.465% during the period from 2025 to 2035.

Which segment is expected to have the largest market value in 2035?

The Hybrid segment is expected to dominate the market, valued at 2.7 USD Billion in 2035.

What are the expected growth rates for the different matrix segments in the US Carbon Composites Market by 2035?

By 2035, the Hybrid, Metal, Ceramic, Carbon, and Polymer segments are expected to reach 2.7 USD Billion, 2.2 USD Billion, 1.5 USD Billion, 3.5 USD Billion, and 1.1 USD Billion respectively.

Who are the major players in the US Carbon Composites Market?

Some of the key players include Celanese Corporation, Honeywell International, Boeing, Northrop Grumman, and General Electric.

Which company is anticipated to have a significant presence in the Carbon segment by 2035?

The Carbon segment is projected to reach 3.5 USD Billion in market value by 2035, indicating strong competition.

What applications are driving the growth of the US Carbon Composites Market?

Key applications include aerospace, automotive, and defense sectors, which are fueling market expansion.

What challenges could impact the US Carbon Composites Market from 2025 to 2035?

Challenges include high manufacturing costs and competition from alternative materials in the market.

How is the US Carbon Composites Market expected to evolve in terms of regionality by 2035?

The market is expected to grow significantly in regions with strong aerospace and automotive industries.

What is the expected CAGR for the US Carbon Composites Market from 2025 to 2035?

The expected CAGR for the US Carbon Composites Market from 2025 to 2035 is 8.007%.

Which segment is expected to have the largest market share in 2024?

In 2024, the Hybrid segment is expected to hold the largest market share, valued at 1.0 USD Billion.

What are the market values of the Ceramic segment in 2024 and 2035?

The Ceramic segment is valued at 0.6 USD Billion in 2024 and is expected to reach 1.5 USD Billion by 2035.

Who are the key players in the US Carbon Composites Market?

Key players in the US Carbon Composites Market include Kordsa Teknik Tekstil A.S., Toray Industries, and Hexcel, among others.

What is the expected market value of the Carbon segment in 2035?

The Carbon segment is expected to reach a market value of 2.6 USD Billion by 2035.

How does the Metal segment's market value compare between 2024 and 2035?

The Metal segment's market value is projected to increase from 0.9 USD Billion in 2024 to 2.2 USD Billion in 2035.

What are some key trends driving the growth of the US Carbon Composites Market?

Key trends include the growing demand for lightweight materials and advancements in composite manufacturing technologies.

What market value is projected for the Polymer segment by 2035?

The Polymer segment is projected to reach a market value of 1.7 USD Billion by 2035.

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