Aircraft Engine Casting Market | Size, Share, Forecast and Growth Analysis

Q: Which market segments are offering high growth opportunities

The investment casting process will offer high growth opportunities in the coming years The winning combination of precision material versatility and the ability to handle complex geometries positions investment casting as the preferred choice for producing high performance airfoils and other critical engine parts

Q: Which region has the highest market growth

Asia Pacific is expected to be the fastest growing market for aircraft engine casting the region is driven by a combination of factors like surging aircraft demand cost competitiveness and government support The region is well positioned to become a major player with increasing market participants and the development of an indigenous supply chain

Q: Who are the top players in the market

Howmet Aerospace Precision Castparts Corp Consolidated Precision Products Doncasters Group Chromalloy Gas Turbine LLC Hitchiner Manufacturing Impro Industries USA Inc MetalTek International and ZOLLERN GmbH Co KG are the leading players in the aircraft engine casting market

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Report Summary

Table of contents

“The Aircraft Engine Casting Market size value was US$ 8.6 Billion in 2023 and is likely to grow at a decent CAGR of 4%, in the long run, to reach US$ 13.2 Billion in 2032”.

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Market Dynamics

Engines remain the biggest application area for casting, alone securing a lion’s share of more than 3/4^th of the market. Cast parts are deployed in every section of the aircraft, right from the fan to the exhaust. The aerospace industry is heavily regulated, and stringent quality and safety standards must be met by manufacturers. This influences the choice of casting processes and materials.

Demand for lightweight yet durable casted parts, advancements in material technology, and the formation of long-term contracts are the key trends shaping market dynamics. Keeping up with rapidly evolving technologies, such as additive manufacturing of advanced materials, requires extensive investments in research & development and workforce training. Shortage of skilled labor is presently a big challenge for stakeholders.

Introduction

Casting allows the production of parts with complex shapes and geometries. This flexibility in design is essential for creating intricate parts like fan frames, turbine exhaust cases, fuel nozzles, burners, and many more. Casting typically generates less material waste compared to other manufacturing processes, contributing to a more environmentally friendly production method. Several materials can be used to make cast parts for aircraft, such as nickel, aluminum, titanium, and steel alloys.

Nickel has applications in the engine segment due to its high-temperature resistance. Titanium is favored for its high strength-to-weight ratio and resistance to corrosion, making it suitable for critical aerospace applications. Aluminum is commonly used in structural parts due to its lightweight nature.

New aircraft programs/variants (B777x and C919) are likely to add momentum during this decade. Boeing and Airbus will reach their peak production rates by the end of 2030. An average of 2,000-2,500 commercial aircraft are to be delivered each year. Leading aircraft manufacturers are increasingly adopting the use of composite materials, particularly for components like fan blades & cases, to enhance performance and efficiency in their engines.

Recent Market JVs and Acquisitions:

A fair number of strategic alliances including M&As, JVs, etc. have been performed over the past few years:

Doncasters acquired Uni-Pol, a global business specializing in the manufacture of superalloy cast parts. This acquisition solidifies their position as a top manufacturer of high-precision alloy components for aerospace.
Veritas Capital, a leading technology and government investment firm, acquired Sequa Corporation. Sequa is the parent company of Chromalloy.

Segments Analysis

Segmentations	List of Sub-Segments	Segments with High Growth Opportunity
Aircraft-Type Analysis	Commercial Aircraft, Regional Aircraft, Military Aircraft, Helicopters, and General Aviation.	Commercial aircraft is expected to remain the biggest demand generator for cast parts during the forecast period.
Engine-Type Analysis	Turbofan, Turboprop, and Others.	Turbofan engine is expected to be the dominant as well as the fastest-growing engine type in the years to come.
Application-Type Analysis	Fans, Compressor, Combustion, Turbine, and Others.	Turbine is expected to be the dominant application, whereas combustion is likely to grow at the fastest rate in the coming years.
Component-Type Analysis	Airfoil Components and Other Components.	Airfoils are expected to be the fastest-growing application category from 2024 to 2032.
Process-Type Analysis	Investment Casting and Other Casting.	Investment casting is expected to be the larger as well as the faster-growing process.
Material-Type Analysis	Nickel, Titanium, Stainless Steel, and Others.	Nickel held the lion’s share in 2023, whereas titanium is expected to be the fastest-growing material.
End-User-Type Analysis	OE and Aftermarket.	OE is expected to be the dominant end-user of the market during the forecast period.
Regional Analysis	North America, Europe, Asia-Pacific, and The Rest of the World.	North America is expected to maintain its reign over the forecast period, whereas Asia-Pacific is likely to expand at the fastest rate.

By Aircraft Type

“Commercial aircraft is expected to remain the biggest demand generator for engine cast parts during the forecast period.”

Based on aircraft type, the market is segmented into commercial aircraft, regional aircraft, helicopter, military aircraft, and general aviation.
Commercial aircraft is expected to remain dominant as well as the fastest-growing aircraft type in the market in the coming years. The commercial aircraft segment is being driven by increasing aircraft deliveries, fleet size, and new efficient variants of existing aircraft. Airbus forecasts a demand for 32,630 single-aisle and 8,220 wide-body aircraft over the next 20 years.
Military aircraft is the second-largest aircraft of the market, which is driven by increasing defense expenditure. Global defense spending rose to US$ 2.1 trillion in 2023, large increases were recorded in Europe, Asia-Pacific, and the Middle East.

By Engine Type

“Turbofan engine is expected to remain the biggest demand generator for cast parts during the forecast period.”

Based on engine type, the market is segmented into turbofan, turboprop, and others.
Turbofan is the most preferred engine category, utilized in all the major aircraft categories: commercial aircraft, regional aircraft, and business jets.
Casting remains one of the most popular manufacturing processes for making crucial turbofan engine parts.

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By Application Type

“Turbine is expected to remain dominant, whereas combustion is expected to be the fastest-growing application during the forecast period.”

Based on application type, the market is segmented into fan, compressor, combustion, turbine, and others.
Turbine is expected to maintain a gigantic share of the market. The turbine is among the hottest parts of the aircraft and is subject to high stress and temperatures. Steel and nickel superalloys are majorly used in turbine applications.
Combustion needs an exceptional synergy of properties: creep resistance, corrosion resistance, fatigue resistance, and high-temperature strength. parts used in the section face a double threat: hot gases on one side and cooler air on the other. Nickel and cobalt-based superalloys are majorly used.

By Process Type

“Investment casting holds a mammoth share in 2023 and is expected to remain the dominant as well as the faster-growing process type during the forecast period.”

The market is segmented based on process type into investment casting and other castings.
Investment casting has a host of advantages, like high accuracy and precision; a superior surface finish; high strength and durability; and design flexibility, making the process the most preferred choice for manufacturing engine parts.
All the leading cast parts suppliers, such as PCC and Howmet, are mainly relying on the investment casting process.
Investment casting is economical and efficient. This process helps minimize material waste and conserve energy.

By Material Type

“Nickel alloys dominated the market in 2023 and are expected to remain dominant, whereas titanium is expected to be the fastest-growing material in the market during the forecast period.”

Based on material type, the market is segmented into nickel, titanium, stainless steel, and others.
Nickel alloys offer superior adhesion, corrosion resistance, and toughness. They are suitable for situations where stress needs to be minimized. They are extensively used in aircraft for parts like turbine blades, combustion chambers, and high-temperature exhaust system parts.
On average, a typical engine contains 1.8 tons of nickel alloys, equivalent to roughly 50% of the engine weight.
The Russo-Ukrainian war led to several changes in market dynamics, especially at the raw material level. Titanium is sourced mostly from Russia by both Boeing and Airbus. The ban on imports from Russia after the war led to an acute increase in the price of all Russian-dependent materials, especially titanium, whose tremor was felt across the value chain including cast parts.

Regional Analysis

“North America is expected to remain the largest market for aircraft engine casting during the forecast period.”

North America is the preferred manufacturing hub of the aerospace industry.
The USA drives North America’s market, The region’s technological advancements, huge R&D investments, and stringent environmental regulations have led to the adoption of sustainable and advanced cast parts.
Approximately 80% of the world’s regional jet fleet is based in North America. In 2022, +2,100 regional jets were in service in North America and Europe.
Despite several setbacks faced by Boeing over the past three years, North America still manages its gigantic lead in the market. Airbus has been increasing its supply chain in North America, including a rise in aircraft assembly. Whereas Boeing is focusing more on its quality.
China, Germany, France, the USA, and India remain the thrust-bearers of the market in the long run.

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Key Players

The market is fairly consolidated with the presence of 50+ players. Market competitors compete based on the quality of their offered products, key players concentrate on growing their production facilities, making R&D investments, and developing infrastructure.

The following are the key players in the aircraft engine casting market:

Here is the list of the Top Players (Based on Dominance)

Precision Castparts Corp.
Doncasters Group
Howmet Aerospace
Consolidated Precision Products
Chromalloy Gas Turbine LLC

Note: The above list does not necessarily include all the top players in the market.

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Report Features

This report provides market intelligence in the most comprehensive way. The report structure has been kept such that it offers maximum business value. It provides critical insights into the market dynamics and will enable strategic decision-making for the existing market players as well as those willing to enter the market.

What Deliverables Will You Get in this Report?

Key questions this report answers	Relevant contents in the report
How big is the sales opportunity?	In-depth Analysis of the Aircraft Engine Casting Market
How lucrative is the future?	The market forecast and trend data and emerging trends
Which regions offer the best sales opportunities?	Global, regional, and country-level historical data and forecasts
Which are the most attractive market segments?	Market segment analysis and Forecast
Which are the top players and their market positioning?	Competitive landscape analysis, Market share analysis
How complex is the business environment?	Porter’s five forces analysis, PEST analysis, Life cycle analysis
What are the factors affecting the market?	Drivers & challenges
Will I get the information on my specific requirement?	10% free customization

Research Methodology

This strategic assessment report from Stratview Research provides a comprehensive analysis that reflects today’s aircraft engine casting market realities and future market possibilities for the forecast period.
The report segments and analyzes the market in the most detailed manner in order to provide a panoramic view of the market.
The vital data/information provided in the report can play a crucial role for market participants as well as investors in the identification of the low-hanging fruits available in the market as well as to formulate growth strategies to expedite their growth process.
This report offers high-quality insights and is the outcome of a detailed research methodology comprising extensive secondary research, rigorous primary interviews with industry stakeholders, and validation and triangulation with Stratview Research’s internal database and statistical tools.
More than 1,000 authenticated secondary sources, such as company annual reports, fact books, press releases, journals, investor presentations, white papers, patents, and articles, have been leveraged to gather the data.
We conducted more than 15 detailed primary interviews with market players across the value chain in all four regions and industry experts to obtain both qualitative and quantitative insights.

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With this detailed report, Stratview Research offers one of the following free customization options to our respectable clients:

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Detailed profiling of additional market players (up to three players)
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Benchmarking of key players on the following parameters: Product portfolio, geographical reach, regional presence, and strategic alliances.

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Frequently Asked Questions (FAQs)

What is aircraft casting?

Casting is the process of creating critical engine parts by pouring molten metal into a mold shaped like the desired part. Casting is an efficient and cost-effective way to produce components that are strong, durable, and highly accurate. Some of the critical parts in an Aircraft that are made with casting are the engine block, turbine blade, compressor blades, impellers, and housings.

What is the forecasted value of the aircraft engine casting market?

The aircraft engine casting market is expected to grow with a CAGR of 4% during the forecast period to reach US$ 13.2 billion by 2032. The market for aircraft casting is fuelled by increasing commercial aircraft production supporting engine production. Casting remains one of the most pivotal roles in metal part fabrication.

What will be the market growth (CAGR) in the coming years?

The aircraft engine casting market is estimated to grow at a CAGR of 4% by 2032, driven by the recovery in commercial aircraft production and rising aircraft fleet size.

Which market segments are offering high-growth opportunities?

The investment casting process will offer high-growth opportunities in the coming years. The winning combination of precision, material versatility, and the ability to handle complex geometries positions investment casting as the preferred choice for producing high-performance airfoils and other critical engine parts.

Which region has the largest market share?

North America is expected to lead the aircraft engine casting market in the coming years. The region has an established industry infrastructure, a highly skilled workforce, and a deep understanding of casting techniques and material properties. Casting companies in North America have established relationships with leading engine OEMs. Major engine manufacturers like Pratt & Whitney and GE are headquartered in North America.

Which region has the highest market growth?

Asia-Pacific is expected to be the fastest-growing market for aircraft engine casting, the region is driven by a combination of factors like surging aircraft demand, cost competitiveness, and government support. The region is well-positioned to become a major player with increasing market participants and the development of an indigenous supply chain.

Who are the top players in the market?

Howmet Aerospace, Precision Castparts Corp., Consolidated Precision Products, Doncasters Group, Chromalloy Gas Turbine LLC, Hitchiner Manufacturing, Impro Industries USA, Inc., MetalTek International, and ZOLLERN GmbH & Co. KG are the leading players in the aircraft engine casting market.

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