The aerospace and defence process materials market is expected to experience impressive expansion between 2025 and 2030, driven by rising production rates, modernization initiatives, and the growing complexity of aerospace manufacturing. Process materials—such as adhesives, sealants, release agents, tooling materials, surface treatments, and composite processing essentials—form the backbone of efficient aerospace production, ensuring structural performance, reliability, and safety across platforms.

As per Stratview Research, the annual demand for aerospace & defence process materials market was USD 410 million in 2024 and is expected to reach USD 469 million in 2025, up 14.4% than the value in 2024.

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As the aerospace sector moves toward advanced composite structures, lightweight materials, and more automated manufacturing environments, the demand for specialized process materials is accelerating. The defence sector, in particular, continues to invest heavily in high-performance materials that support stealth capabilities, thermal resistance, and extended durability in extreme operating conditions.

Market Drivers
A key growth driver is the steady rise in commercial aircraft manufacturing as airlines upgrade fleets for fuel efficiency and operational flexibility. Composites and next-generation alloys require specific curing, bonding, and processing materials, expanding demand for advanced process solutions. Defence modernization programs—ranging from fighter aircraft upgrades to missile system development—further amplify requirements for high-strength adhesives, protective coatings, and precision tooling systems.

Additionally, the increasing adoption of additive manufacturing and automated composite layup systems boosts the need for compatible resins, films, molds, and consumables designed to withstand high temperatures and complex geometries. Process reliability, quality assurance, and material traceability are gaining importance, pushing suppliers to innovate in digital monitoring and high-precision formulation.

Key Trends
A prominent trend shaping the market is the shift toward environmentally compliant materials with low VOC emissions, recyclable content, and improved user safety. Automation is also influencing the selection of process materials that deliver consistent performance under robotic application systems. The growing use of out-of-autoclave composites and rapid-curing resins is reshaping production timelines and material selection criteria.

Opportunities from 2025 to 2030
Substantial opportunities lie in supporting the expanding electric aircraft ecosystem, where lightweight adhesives, thermal management materials, and protective coatings are essential. Growth in unmanned aerial systems (UAS), space exploration missions, and hypersonic defence programs further widens the market’s horizon. Suppliers offering tailored formulations, customizable kits, and enhanced durability solutions will be well-positioned for long-term growth.

Overall, the aerospace and defence process materials market is on a robust trajectory, driven by technological advancement, manufacturing evolution, and sustained global investment in high-performance aviation and defence platforms.