US Aerospace Forging Market Size & Share Analysis 2025 - Trends & Forecasts, 2018-2034

August, 2025 123 Pages

US Aerospace Forging Market Size

The US Aerospace Forging Market size is estimated at $6.15 Billion in 2025. Further, the market is poised to reach $9.6 Billion in 2034, registering a growth rate (CAGR) of 5.1%.

The comprehensive report provides an in-depth analysis of the US Aerospace Forging industry. This 10th edition is developed based on our meticulous research of primary and secondary data sources, ensuring accuracy and reliability. The analytical study covers market size across By Material (Aluminum Alloy, Titanium, Stainless Steel, Others), By Aircraft (Fixed Wing, Rotary Wing), By Application (Rotors, Turbine Disc, Shafts, Fan Case, Others), By End-User (Commercial, Military). It offers key drivers, challenges, and growth forecasts into the market current state and future prospects from 2018 to 2034. Leading companies and their market shares are included in the study.

US Aerospace Forging Market Analysis

The U.S. aerospace forging market is advancing as aircraft manufacturers demand high-strength, fatigue-resistant components for critical structural and engine applications. Forged aerospace parts—ranging from landing gear components to turbine discs and wing spars—are primarily made from high-performance alloys such as titanium, aluminum, and nickel-based superalloys to withstand extreme pressure and temperature conditions. With the push for fuel-efficient and lightweight aircraft, precision forging techniques like isothermal and closed-die forging are being increasingly adopted to enhance material integrity while minimizing waste. Additionally, the rise of hypersonic and next-generation military aircraft is driving demand for ultra-high-temperature-resistant forged materials. However, supply chain disruptions and fluctuations in raw material availability are prompting U.S. aerospace forging companies to invest in domestic sourcing, advanced automation, and additive manufacturing integration to streamline production. As FAA and DoD regulations emphasize structural integrity and safety, innovations in metallurgical processing and quality control continue to shape the aerospace forging landscape.
Aerospace forging is critical for producing high-strength, lightweight components like landing gear and engine parts, with a focus on advanced alloys and precision engineering. A Boeing report highlighted that forged titanium components have improved the fatigue life of aircraft structures by 30%, enhancing safety and durability. https://www.boeing.com/

US Aerospace Forging Market Trends

Aerospace Forging Market: High-Strength Titanium and AI-Optimized Forging Techniques Driving Aircraft Manufacturing Efficiency

The US aerospace forging market is evolving as manufacturers adopt AI-driven optimization techniques and next-generation titanium alloys to improve component strength while reducing material waste. With the aerospace industry facing ongoing supply chain constraints, forging companies like Precision Castparts Corp. and Arconic are leveraging digital twin simulations to enhance die design, reducing lead times for critical engine and structural components. The demand for high-strength titanium forgings has surged, especially for applications in commercial aircraft landing gears and military-grade turbine discs, where extreme durability is required. Additionally, the shift toward sustainable manufacturing is driving the adoption of closed-die forging processes, which minimize excess material usage while maintaining aerospace-grade quality standards.

US Aerospace Forging Market Opportunity– Growth in High–Strength Titanium and Aluminum Alloy Components

The increasing production of commercial aircraft, military jets, and space vehicles is driving demand for forged titanium and aluminum alloy components that offer high strength–to–weight ratios and corrosion resistance. Aerospace forging leaders like ATI Inc., Arconic, and Bharat Forge are investing in precision forging technologies to produce critical aircraft parts, including landing gear, engine disks, and structural fittings. As US military modernization and space exploration initiatives expand, the need for aerospace–grade forged components is expected to grow significantly.

Segment Analysis

US Aerospace Forging Market By Material (Aluminum Alloy, Titanium, Stainless Steel, Others)

Aluminum Alloy and Titanium
Aluminum alloy plays a dominant role in the US aerospace forging market due to its lightweight nature, high strength, and excellent corrosion resistance. It’s widely used in structural components like fuselage frames, wing structures, and landing gear parts, where weight reduction directly enhances fuel efficiency and aircraft performance. Titanium follows closely as a preferred material for critical, high-stress applications such as engine components and fasteners. Its exceptional strength-to-weight ratio, heat resistance, and durability make it vital in both commercial and military aviation, despite its higher production cost.
Stainless Steel and Others
Stainless steel remains essential for parts requiring high strength, wear resistance, and the ability to withstand extreme conditions, such as landing gear assemblies and hydraulic systems. Its resilience against stress and temperature fluctuations ensures long service life in demanding aerospace applications. The Others category includes emerging advanced alloys and specialized materials designed for specific performance requirements, such as nickel-based superalloys used in jet engine components. The development of innovative materials reflects the industry’s focus on enhancing safety, efficiency, and operational longevity.

US Aerospace Forging Market By Aircraft (Fixed Wing, Rotary Wing)

Fixed Wing Aircraft
Fixed wing aircraft dominate the US aerospace forging market due to their widespread use in commercial, military, and private aviation. These aircraft require high-strength, lightweight forged components for critical structural and engine parts, including wing spars, landing gear, and turbine blades. Materials like aluminum alloys and titanium are extensively used to enhance fuel efficiency, performance, and durability. The continuous growth of commercial air travel and military fleet modernization programs drives demand for advanced forgings in this segment.
Rotary Wing Aircraft
Rotary wing aircraft, including helicopters, represent a smaller but vital portion of the market, requiring specialized forged components for rotor hubs, transmission systems, and airframe structures. These aircraft operate in diverse and demanding environments, making durability and resistance to fatigue crucial. Stainless steel and high-performance alloys are often used to withstand heavy mechanical loads and vibrations. The growing demand for military and emergency response helicopters fuels the need for robust, precision-forged parts in this segment.

US Aerospace Forging Market By Application (Rotors, Turbine Disc, Shafts, Fan Case, Others)

Rotors and Turbine Discs
Rotors and turbine discs represent key applications in the US aerospace forging market, driven by their critical role in aircraft engine performance and safety. Turbine discs, forged primarily from high-strength materials like titanium and nickel-based superalloys, must withstand extreme temperatures and rotational forces. Rotors, essential for both fixed-wing and rotary-wing aircraft, require exceptional durability and precision to ensure efficient power transmission and flight stability. The increasing demand for fuel-efficient and high-performance jet engines keeps these components at the forefront of aerospace forging innovation.
Shafts, Fan Cases, and Others
Shafts and fan cases play crucial roles in transmitting mechanical power and protecting engine components, demanding high-strength, lightweight materials like aluminum alloys and stainless steel. Forged shafts provide the durability and resistance needed to handle high stress and rotational speeds, while fan cases maintain structural integrity around engine fans, protecting against foreign object damage. The Others category includes landing gear parts, airframe components, and specialized fittings, reflecting the broad application of forged materials in ensuring aircraft safety, performance, and longevity.
 

US State-wise Analysis

US consumers remain optimistic about the economy but caution around spending continue to persist across segments. The US GDP is forecast to register 2.7% y-o-y growth in 2025 and around 2.1% in 2026. Leading contributors to the economy including California, Texas, New York, Florida, Illinois, Pennsylvania, Ohio, Georgia, Washington, New Jersey and others remain key markets in 2025. On the other hand, ten states are likely to register rapid GDP growth rate of 4.2% to 7% including Arkansas, Alabama, Mississippi, Wyoming, Idaho, Utah, New Hampshire, Vermont, West Virginia, and Wisconsin according to the Bureau of Economic Analysis. With inflation rate forecasts to remain around 2%, the country presents robust market prospects for Aerospace Forging companies.

Competitive Landscape

Arconic Inc. Aerospace Forging Product Portfolio

Arconic Inc. is a leading aerospace forging supplier, specializing in advanced aluminum and titanium forgings for aircraft structures and engine components. The company's high-strength forged products are used in landing gear, fuselage frames, and turbine engine discs, ensuring durability and performance in extreme conditions. Arconic’s patented forging technologies enhance material strength and reduce weight, making them a preferred choice for commercial and military aerospace applications.

Precision Castparts Corp. Aerospace Forging Product Portfolio

Precision Castparts Corp. (PCC) is a key player in aerospace forging, producing nickel, titanium, and stainless-steel forgings for aircraft engines, airframes, and landing gear systems. The company’s precision-engineered components support major aircraft manufacturers, including Boeing and Airbus. PCC’s advanced isothermal and closed-die forging capabilities allow for the production of high-strength, lightweight components that enhance aircraft efficiency and performance.
The US Aerospace Forging Market is highly competitive with key players including Arconic (US), Bharat Forge (India, US plants). Companies investing in strong distribution networks and brand recognition continue to gain steady revenue growth in the industry. Analysis of the leading US Aerospace Forging companies identifies that widening portfolio through new launches and catering to niche segments remains the most potential growth strategy.
 

US Aerospace Forging Report Segmentation and Scope

Aerospace forging is a manufacturing process that shapes metal components under high pressure to create strong, durable parts for aircraft and spacecraft. Using materials like titanium and aluminum alloys, forging enhances the mechanical properties of components such as landing gear, engine parts, and structural frames. This process ensures high strength, reliability, and resistance to extreme conditions in aerospace applications.

By Material
Aluminum Alloy
Titanium
Stainless Steel
Others
By Aircraft
Fixed Wing
Rotary Wing
By Application
Rotors
Turbine Disc
Shafts
Fan Case
Others
By End-User
Commercial
Military
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