Aircraft Thermoforming Market Analysis | 2024-2034

“The Aircraft Thermoforming Market size was valued at US$ 238.3 million in 2023 and is likely to grow at a significant CAGR of 7.0% in the long run to reach US$ 519 million in 2034.”

Market Dynamics

Introduction

Plastic parts are most commonly used in aircraft cabin interiors. Thermoforming is one of the major processes in producing plastic parts. Thermoforming involves heating large sheets of thermoplastics and shaping them to form the desired parts. The transformative process offers lightweight, aesthetic appeal, flame retardant, durability, design flexibility, sustainability, and rapid development of parts.

The versatility and cost-effectiveness of this process make it ideal for various cabin interior plastic parts, such as tray tables, seat backs, footwell trays, and armrests. The versatility of thermoforming also means that it can accommodate various materials and textures, allowing manufacturers to innovate while adhering to safety and regulatory standards. The adoption of thermoformed parts is becoming integral to the advancement of aircraft interiors.

Recent Market JVs and Acquisitions

Several strategic alliances, including M&As, JVs, etc., have been formed over the past few years. One of the key alliances is:

• In April 2018, Ducommun Incorporated (NYSE) completed the acquisition of Certified Thermoplastics Co., LLC (CTP).

Segments Analysis

By Aircraft Type

“Narrow-body aircraft are expected to continue driving the demand for thermoformed parts in the coming years.”

• The aircraft thermoformed parts market is primarily segmented into narrow-body aircraft, wide-body aircraft, regional aircraft, and business jets.
• Boeing’s B737 and Airbus’ A320 are the key demand generators of the narrow-body aircraft segment’s market.
• The market entry of Airbus’ A321XLR, COMAC’s C919, and the expected entry of Boeing’s B777X are the key factors propelling the demand for thermoformed parts in the coming years.
• Wide-body aircraft are likely to witness the fastest growth in the market during the forecast period, mainly driven by the expected entry of B777X.
• Overall, the trend towards sustainable materials and innovative designs in thermoforming is expected to grow across all segments, improving aesthetics, functionality, and durability in aircraft interiors.

By Application Type

“Seats are projected to remain the dominant application in the aircraft thermoformed parts market in the foreseeable future.”

• The market is segmented into floor panels, galleys, seats, lavatories, stowages, and others.
• Seats are driven by a high focus on passenger comfort and aesthetics. The flexibility of the thermoforming process allows manufacturers to create complex shapes and custom features, such as integrated stowage and advanced cushioning, catering to diverse passenger needs and preferences.
• For galleys, thermoformed parts facilitate the design of efficient, streamlined layouts that maximize space and enhance operational functionality.
• Stowages gained from thermoformed parts' lightweight and durability enable a cunning design that optimizes cabin space without compromising structural integrity. Thermoformed parts used in floor panels are not only lightweight but also designed to improve insulation and soundproofing, enhancing overall cabin comfort.

By Material Type

“Polyvinyl chloride (PVC) currently holds the largest share in the market and is also anticipated to experience the fastest growth during the forecast period.”

• The market by material type is segmented into polyvinyl chloride (PVC), polycarbonate (PC), and Others.
• Polyvinyl chloride (PVC) is likely to remain the dominant material, due to its versatility, cost-effectiveness, and durability, making it ideal for aircraft interiors, such as food trays, seat backs, armrests, and seat cladding, mainly for its impact resistance and durability.
• Its lightweight nature aids fuel efficiency, while resistance to chemicals, moisture, and UV makes their wider usage in direct access areas of passengers. PVC also offers sustainability as it is recyclable.
• Polycarbonate (PC) is crucial for small aircraft parts due to its high impact resistance and optical clarity, making it suitable for developing lightweight thermoformed parts for cabin interiors, such as window trim, lavatories, and lighting fixtures, enhancing design flexibility and overall efficiency in aviation.
• Both PVC and PC are well-suited for the thermoforming process, enabling the creation of complex shapes and thin-walled parts that reduce weight while maintaining structural integrity.

By End-User Type

“OE is the dominant end-user segment and is expected to maintain its leadership in the market throughout the forecast period.”

• By end-user type, the market is segmented into OE and aftermarket.
• Expected rise in production rates of key aircraft programs, such as B737 and A320 in the foreseeable future is likely to drive the market’s demand at OE level.
• As per Boeing’s Commercial Market Outlook 2023-2042, the commercial and regional aircraft fleet size is estimated to reach 50,170 in 2043 from 26,750 in 2023, with a projected 43,975 new aircraft deliveries during the next 20 years.
• The aftermarket is also witnessing healthy growth in the market during the forecast period, due to increasing focus on aircraft maintenance, refurbishment, and customization. Additionally, the trend toward retrofitting older aircraft with modern, eco-friendly materials aligns with sustainability initiatives, driving the need for innovative thermoformed parts.

Regional Analysis

“North America is expected to remain the largest region of the market, whereas the Asia-Pacific region is projected to experience rapid growth during the forecast period.”

• The region is segmented into North America, Europe, Asia-Pacific, and the rest of the world.
• Several key factors, including an established and efficient supply chain that facilitates quick access to raw materials, significant R&D investments that drive innovation in materials and processes, and a highly skilled workforce proficient in aerospace manufacturing are driving the market’s demand in North America.
• The Asia-Pacific region is poised for rapid growth, driven by the continuous rise in new aircraft deliveries to support increasing air passenger traffic, and the huge order backlog of the newly entered aircraft, C919. Additionally, joint ventures between local and international aerospace companies facilitate technology transfer and government initiatives to promote domestic production and reduce reliance on imports boosting high-growth opportunities in the region.
• Overall, strict environmental regulations also encourage the use of lightweight, sustainable materials fueling the demand for innovative thermoformed parts in aircraft interiors.

Key Players

The market is fragmented with the presence of several players across regions. Most of the major players compete in some of the governing factors, including price, service offerings, regional presence, etc. The following are the key players in the Aircraft Thermoforming Market.

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

• HEICO Corporation
• Aerofoam Industries, LLC
• Curbell Plastics, Inc.
• Universal Plastics Group, Inc.
• Belgraver B.V.
• Brentwood Industries, Inc.
• Emerald Aero Group
• DUROtherm Kunststoffverarbeitung GmbH
• Formed Plastics, Inc.
• Aereos, INC.

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

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Report Features

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Research Methodology

• This strategic assessment report from Stratview Research provides a comprehensive analysis that reflects today’s aircraft thermoforming market realities and future market possibilities for the forecast period. 
• The report segments and analyzes the market in the most detailed manner 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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• Detailed profiling of additional market players (up to three players)
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• Benchmarking of key players on the following parameters: Service portfolio, geographical reach, regional presence, and strategic alliances

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