“The aircraft propulsion composite blades market size was US$ 70 million in 2024 and is likely to grow at a CAGR of more than 3% in the long run to achieve cumulative sales of more than US$ 480 million during 2025-2030.”
Market Dynamics
Introduction
The propeller system on an aircraft provides a method of propulsion so the aircraft can move forward in the air. The system primarily consists of blades, a hub, and a spinner. With the plethora of advantages composite materials offer (weight reduction, fuel efficiency, durability, enhanced aerodynamic performance, reduced maintenance cost, and the ability to withstand extreme operation conditions), the trend in the market has been to replace metal propeller blades with composite ones. Wood props are only found on some small aircraft.
Aircraft propulsion composite blades are manufactured using carbon and hybrid composites. It offers a superior strength-to-weight ratio and a longer lifespan and is more cost-efficient than conventional metal blades. These blades are manufactured using a variety of processes, including overmolding+RTM (Resin Transfer Molding), overmolding, and prepreg. Blade manufacturers are increasingly adopting composite materials as modern aircraft designs (in military transport aircraft, regional turboprops, and general aviation) employ more blades, which is challenging to achieve with traditional metallic blades. The market growth is driven by advancements in aircraft designs, increasing global turboprop fleet, and expansion in military airpower.
Market Drivers:
Some of the key factors driving this market are a growing fleet of general aviation and military transport aircraft, high penetration of composite blades, development of multi-bladed propellers, and the emergence of electric aircraft.
Market Challenges:
The aircraft composite blades market faces several challenges despite its high growth potential. High production costs associated with composite blade production, stringent certification, and regulatory challenges, and suspended production of some popular aircraft programs are the growth limiters for the market. Aging piston aircraft and their retirement, along with MRO bottlenecks, also pose challenges to the market.
Recent Developments:
- In December 2022, MT-Propeller announced that it had completed the first test flight of its 11-bladed propeller (the first in the world). The manufacturer has previously made five, seven, and nine-bladed propellers.
Recent M&As, Strategic Alliances and Partnerships:
Market players perform mergers and form strategic alliances and partnerships in the market. Some recent developments in the past few years:
- In March 2024, Hartzell Propeller expanded its portfolio into light-sport aircraft by completing the acquisition of WhirlWind Propellers. WhirlWind makes composite constant-speed and ground-adjustable propellers for the light-sport, experimental, and unmanned aircraft markets.
- In November 2018, UTC acquired Rockwell Collins to form Collins Aerospace. This acquisition was a significant move in the aerospace industry, and the restructuring created a new market leader.
Market Segments' Analysis
Segmentations
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List of Sub-Segments
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Segments with High Growth Opportunity
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Platform Type Analysis
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Military Transport Aircraft, Regional Turboprops, and General Aviation
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General Aviation is expected to grab the largest share of the market during the forecast period.
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Engine Type Analysis
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Turboprop and Piston
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Turboprop is expected to be the bigger category during the forecast period.
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Material Type Analysis
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Carbon Composites and Hybrid Composites
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Carbon Composite is anticipated to record the best growth trajectory during the forecast period.
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By Process Type Analysis
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Overmolding+RTM, Overmolding, and Prepreg.
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Overmolding+RTM is likely to be the dominant process during the forecast period.
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End-User-Type Analysis
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OE Market and MRO Market
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OE Market is expected to record the highest growth during the forecast period.
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Regional Analysis
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North America, Europe, Asia-Pacific, and Rest of the World
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North America is likely to be the leading market, whereas Asia-Pacific is poised to be the fastest-growing market during the forecast period.
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By Platform Type
“General Aviation is expected to be the market's leading platform during the forecast period.”
The aircraft propulsion composite blades market is segmented into military transport aircraft, regional turboprops, and general aviation. Although military transport aircraft and regional turboprops require a higher number of blades than general aviation, the growing fleet of general aviation due to their rising applications in agriculture, medical, and other fields is expected to drive the category’s growth during the forecast period. The regional turboprops market is anticipated to grow at the fastest pace during the same period.
By Material Type
“Carbon composite is expected to be the most sought-after material in the market during the forecast period.”
Carbon composite blades offer significant advantages to aircraft manufacturers, such as weight savings, reduced noise and vibration, durability, and longevity. Compared to glass composites, they provide higher stiffness and lower density, allowing a thinner blade profile while producing propeller blades. The material is expected to maintain its position in the market during the forecast period.
By End-User Type
“OE is expected to be the fastest-growing market during the forecast period.”
OE and MRO, both end-use categories, were severely impacted by the COVID-19 pandemic. Post-COVID, the market gradually came back to its feet. The OE market is likely to grow with the fastest CAGR during the forecast period, as composite blades are highly durable and can withstand multiple repairs and overhauls without requiring total replacement.
Regional Analysis
“North America is estimated to remain the largest market for Aircraft Propulsion Composite Blades during the forecast period.”
In terms of region, North America is expected to remain the largest market for aircraft propulsion composite blades during the forecast period. The region is a manufacturing hub for aircraft that use high-value composite blades. The presence of leading propeller blade manufacturers such as Hartzell Propeller, Collins Aerospace, and McCauley Propeller further strengthens its position.
Asia-Pacific is estimated to record the highest growth during the forecast period. This is attributable to the growing demand for regional air connectivity and manufacturing expansion of global aircraft OEMs in the APAC region.
Key Players
All 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 propulsion composite blades market.
Here is the list of the Top Players (based on dominance)
- Hartzell Propeller
- MT-Propeller
- Collins Aerospace
- Dowty Propeller
- McCauley Propeller
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 most comprehensively. The report structure has been kept so that it offers maximum business value. It provides critical insights into market dynamics and will enable strategic decision-making for existing market players and those willing to enter the market. The following are the key features of the report:
- Market structure: Overview, industry life cycle analysis, supply chain analysis.
- Market environment analysis: Growth drivers and constraints, Porter’s five forces analysis, SWOT analysis.
- Market trend and forecast analysis.
- Market segment trend and forecast.
- Competitive landscape and dynamics: Market share, Service portfolio, New Product Launches, etc.
- COVID-19 impact and its recovery curve
- Attractive market segments and associated growth opportunities.
- Emerging trends.
- Strategic growth opportunities for the existing and new players.
- Key success factors.
The Aircraft Propulsion Composite Blades market is segmented into the following categories.
Aircraft Propulsion Composite Blades Market by Platform Type
- Military Transport Aircraft (Regional Analysis: North America, Europe, Asia-Pacific, and Rest of the World)
- Regional Turboprops (Regional Analysis: North America, Europe, Asia-Pacific, and Rest of the World)
- General Aviation (Regional Analysis: North America, Europe, Asia-Pacific, and Rest of the World)
Aircraft Propulsion Composite Blades Market by Engine Type
- Turboprop (Regional Analysis: North America, Europe, Asia-Pacific, and Rest of the World)
- Piston (Regional Analysis: North America, Europe, Asia-Pacific, and Rest of the World)
Aircraft Propulsion Composite Blades Market by Material Type
- Carbon Composites (Regional Analysis: North America, Europe, Asia-Pacific, and Rest of the World)
- Hybrid Composites (Regional Analysis: North America, Europe, Asia-Pacific, and Rest of the World)
Aircraft Propulsion Composite Blades Market by Process Type
- Overmolding+RTM (Regional Analysis: North America, Europe, Asia-Pacific, and Rest of the World)
- Overmolding (Regional Analysis: North America, Europe, Asia-Pacific, and Rest of the World)
- Prepreg (Regional Analysis: North America, Europe, Asia-Pacific, and Rest of the World)
Aircraft Propulsion Composite Blades Market by End-User Type
- OE Market (Regional Analysis: North America, Europe, Asia-Pacific, and Rest of the World)
- MRO Market (Regional Analysis: North America, Europe, Asia-Pacific, and Rest of the World)
Aircraft Propulsion Composite Blades Market, by Region
- North America (Country Analysis: The USA, Canada, and Mexico)
- Europe (Country Analysis: Italy, France, The UK, Switzerland, and Rest of Europe)
- Asia-Pacific (Country Analysis: China, Pacific, and Rest of Asia-Pacific)
- Rest of the World
Research Methodology
This strategic assessment report from Stratview Research provides a comprehensive analysis that reflects today’s Aircraft Propulsion Composite Blades 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 in helping market participants and investors identify the low-hanging fruits available in the market and formulate growth strategies to expedite their growth process. This report offers high-quality insights and results from 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. Over 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 25 detailed primary interviews with market players across the value chain in all four regions and industry experts to obtain qualitative and quantitative insights.
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