Aerospace Foam Market - Forecast(2023 - 2028)

By Type: Polyurethane Foam, Polyethylene Foam, Ceramic Foam, Metal Foam, Melamine Foam, Polyethylene Terephthalate Foam, Polyvinyl Chloride Foam, Specialty High-Performance Foam and Others.

By Application: Aircraft Seats, Aircraft Floor Carpets, Cabin Walls and Ceilings, Flight Deck Pads, Overhead Stow Bins and Others.

By End-use Industry: Commercial Aircrafts, Military Aircrafts, Helicopters and Others.

By Geography: North America, Europe, Asia-Pacific, South America and the Rest of the World.

Aerospace Foam Market Drivers

Surge in the Demand for Lightweight and Fuel-Efficient Aircraft:

The carbon emissions per kilometer can be reduced by using less weighted aircraft for conventionally powered aircraft. With the imposition of stringent emission regulations by the government and its plan to regulate higher emissions standards in the years to come, lightweight construction is gaining importance each day. Typically, aircrafts utilizing aerospace foams for various applications are contributing to reduced weight. Therefore, the demand for lightweight aircraft is increasing rapidly, which in turn is increasing the demand for aerospace foams. Also, to obtain a 6 to 8 percent improvement in fuel economy, 10% of the vehicular weight must be reduced, according to the U.S. Department of Energy Vehicle Technology Office. Moreover, to reduce fuel burn, the aircraft design must be more efficient. It should move through the air easily, utilize electricity to power the propulsion system and ought to be lightweight as is safely practical. For instance, according to the National Renewable Energy Laboratory, electric and hybrid-electric aircraft are projected to operate at 85%–90% efficiency and to be 20%–40% more efficient than piston and turbine aircraft. 

Growth in Aerospace Industry:

In the aerospace industry, aircraft foams such as polyurethane foam, polyethylene foam, ceramic foam, metal foam and others are applied in aircraft seats, aircraft floor carpets, cabin walls and ceilings, flight deck pads, overhead stow bins and other applications. The aerospace industry is growing, for instance, according to the Indian Brand Equity Foundation (IBEF), the Indian aerospace & defence (A&D) market is projected to reach US$70 billion by 2030, driven by the burgeoning demand for advanced infrastructure and government thrust. Moreover, in 2021, according to the International Trade Administration (ITA), the Dutch Government has increased its investments in the aerospace industry, investing €1.5 billion (US$1.57 billion) over the next five years, with a one-time increase of €1.2 billion (US$1.26 billion) in 2019 and an annual increase of €162 million (US$170 million) in the following years. Thus, increasing investments in the aerospace industry will require more aerospace foams for manufacturing aircraft parts, which will drive the demand for the aerospace foam market during the forecast period.

Aerospace Foam Market Challenges

Fluctuation in Raw Material Production and Costs:

Increment in the cost of basic raw materials, high global demand and reduced supply make aerospace foams more expensive. The aerospace foam industry, which provides an advantage in various aerospace applications, is concerned about the substantial increase in the cost of basic raw materials. Demand and supply factors varying from one raw material to another affect the cost of aerospace foams such as polyurethane foam, polyethylene foam, ceramic foam, metal foam and others. It becomes difficult for manufacturers to sustain themselves globally, due to the fluctuations in raw material prices, affecting their operating margins on aerospace foam. For instance, according to Delta Trade, polyurethane foam prices increased by 20% and have become more expensive from October 2020 and the next increases were already announced. Polyurethane foam is getting costlier due to the disruptions in the production of toluene diisocyanates (TDI) and polyols as raw materials, which are the main ingredients of the foam. Thus, the fluctuations in raw material production and costs of aerospace foams will create hurdles for the growth of the aerospace foam market.

Aerospace Foam Industry Outlook

The top 10 companies in the aerospace foam market are:

1. BASF SE
2. Huntsman Corporation
3. Armacell
4. Boyd Corporation
5. Evonik Industries
6. Sabic
7. Rogers Corporation
8. Zotefoams Plc
9. General Plastics Manufacturing Company
10. ERG Materials

Recent Developments

• In July 2022, SABIC launched a specialized portfolio of SABIC PP compounds for foam injection molding (FIM). New mineral-reinforced SABIC PPC F9005, PPC F9007 and PPC F9015 grades can help deliver excellent aesthetics for visible aircraft interior parts with complex geometries, such as door panels and trim, seat and trunk cladding, A/B/C/D pillar covers and center consoles.
• In November 2019, Evonik Corporation expanded its production of ROHACELL high-performance rigid, closed-cell foams at its Mobile, Ala., site, due to increasing demand for lightweight construction materials for specialty applications.
• In March 2019, Zotefoams Plc’s ZOTEK F was selected as the material of choice by Thompson Aero Seating, a leading supplier of premium aircraft seating, as the lightweight, fire-resistant solution for its new high-tech seating range, as it offered a 1.6kg reduction in weight per seat.

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