Aerospace Foam Market Size To Reach $11.71 Billion By 2033

Aerospace Foam Market Growth & Trends

The global aerospace foam market size is estimated to reach USD 11.71 billion by 2033, registering a CAGR of 6.8% from 2025 to 2033, according to a new report by Grand View Research, Inc. Increasing demand for fuel-efficient aircraft, due to extensively increasing fuel prices, has propelled manufacturers to minimize aircraft weight. Hence, manufacturers have adopted the installation of aerospace foams in various aircraft applications, such as flight deck pads, carbon walls & ceilings, aircraft seats, and aircraft floors, which contribute to the formulation of lightweight aircraft. Aerospace foam, especially Polyurethane (PU)- and Polyethylene (PE)-based foams are primarily utilized across the aircraft for insulation purposes, avoiding any thermal and air pressure exchange between the aircraft and the other environment.

Furthermore, the requirement for comfortable and luxurious seating across the aircraft to provide a pleasant flight experience has increased product demand across the airline industry. This is anticipated to boost industry growth over the forecast period. North America is expected to benefit from a rapidly expanding airline industry across the U.S., where aerospace foams are mainly utilized in applications, such as sealants for flight deck pads, carbon walls & ceilings, aircraft seats, and aircraft floors. High consumer disposable income levels and luxurious standards as a preference for air travel are also anticipated to foster demand for a comfortable seating experience, leading to a rise in aerospace foam sales.

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Aerospace Foam Market Report Highlights

• In terms of end-use, the commercial aviation dominated the market in terms of revenue, accounting for a share of 29.64% in 2024. Increasing passenger traffic, coupled with rising demand for aircraft retrofitting and cabin upgrades, continues to propel the market in this segment.

• In terms of revenue and volume, the PU foam segment accounted for the largest share in 2024, owing to its wide application usage. PU foams are used for the insulation of aircraft, baggage sections, ceilings and walls, and separators between the class segments and lavatories.

• In terms of application, the cabin walls & ceilings led the aerospace foam industry, accounting for a revenue share of 26.78% in 2024. Owing to the widespread usage of aerospace foam, especially PU foam, across the chassis of the aircraft.

• North America led the global industry in 2024 due to high competition among major aircraft manufacturers and increased demand for private aircraft due to high consumer disposable income levels.

Aerospace Foam Market Segmentation

Grand View Research has segmented the global aerospace foam market based on foam type, application, end-use, and region:

Aerospace Foam Foam Type Outlook (Volume, Kilotons; Revenue, USD Million, 2021 - 2033)

• Polyurethane Foam

• Polyethylene Foam

• Melamine Foam

• Metal Foam

• Polyimide Foam

• Polyethylene Terephthalate Foam

• Polyvinyl Chloride Foam

• Specialty High Performance Foam

Aerospace Foam Application Outlook (Volume, Kilotons; Revenue, USD Million, 2021 - 2033)

• Flight Deck Pads

• Cabin Walls & Ceilings

• Aircraft Seats

• Aircraft Floor

• Others

Aerospace Foam End-use Outlook (Volume, Kilotons; Revenue, USD Million, 2021 - 2033)

• General Aviation

• Commercial Aviation

• Military Aircraft

• Rotary Aircraft

Aerospace Foam Regional Outlook (Volume, Kilotons; Revenue, USD Million, 2021 - 2033)

• North America

  • U.S.

  • Canada

  • Mexico

• Europe

  • Germany

  • UK

  • France

  • Italy

• Asia Pacific

  • China

  • India

  • Japan

  • South Korea

• Latin America

  • Brazil

  • Argentina

• Middle East & Africa

  • GCC Countries

  • South Africa

List of Key Players in the Aerospace Foam Market

• Boyd Corporation

• Evonik Industries AG

• ERG Aerospace Corporation

• SABIC

• BASF SE

• ZOTEFOAMS PLC

• General Plastics Manufacturing Company

• Solvay

• UFP Technologies, Inc.

• Recticel NV/SA

• NCFI Polyurethanes

• DuPont

• Rogers Corporation

• ARMACELL