The global aircraft engine forging market has evolved significantly as aviation technology advances, and sustainability achievements shape the industry’s direction heading into 2025. Known for its essential role in ensuring engine performance, reliability, and longevity, the market for forged engine components is witnessing transformative changes driven by innovations in manufacturing processes, materials science, regulatory frameworks, and end-user requirements. Expert insights and recent data highlight shifting trends, emerging opportunities, and challenges that will continue to redefine the value chain for aircraft engine forging over the next several years.
As of 2025, the aircraft engine forging market is undergoing a paradigm shift fueled by robust air travel recovery, surging demand for new-generation narrow-body jets, and increased replacement cycles for legacy engines. Alongside the traditional commercial aviation segment, rising defense budgets and tactical air fleet modernization initiatives are pushing military engine manufacturers to place greater orders for forged components. According to industry analysts at Frost & Sullivan, the commercial aircraft segment alone is expected to account for nearly 70% of forging demand by volume, but the military market is expanding at a CAGR surpassing 5% due to sustained investments in fighter propulsion systems.
One of the most striking trends in 2025 is the accelerated adoption of advanced forging technologies—such as isothermal forging, precision closed-die forging, and rotary forging—which provide superior material properties and dimensional accuracy compared to conventional methods. These innovations are enabling manufacturers to produce more lightweight, high-strength engine parts with complex geometries, fulfilling the requirements of newer ultra-high bypass ratio turbofans and regional jets.
https://pmarketresearch.com/chemi/diphenylmethanol-market
Dr. Magnus Huber, Director of Manufacturing Technology at MTU Aero Engines, recently commented in an industry think tank: “Forging remains irreplaceable for critical rotating components, particularly blisks, compressor disks, and turbine shafts. The move towards digital and automated forging lines, empowered by in-situ metrology and AI algorithms, is reducing scrap rates while enhancing mechanical consistency.” Huber’s remarks reflect the broader sector-wide investments in digital twin solutions and real-time process monitoring, which are driving efficiency in both legacy and new forging facilities.
The quest for sustainability and emissions reduction has also profoundly influenced the aircraft engine forging market in 2025. Aviation OEMs and their Tier-1 suppliers are under increasing pressure from regulators and airline operators to minimize the carbon footprint associated with engine production. This is leading to a proliferation of eco-friendly forging practices—including the use of recycled or lower-carbon feedstock materials, electrification of heating systems, and closed-loop water management. MarketsandMarkets research suggests that, by the end of this year, more than 30% of forged engine components acquired by leading airframe builders will incorporate at least one sustainable process innovation compared to the baseline practices of 2019.
https://pmarketresearch.com/auto/environmentally-friendly-carbonization-furnace-market/
Material trends continue to be decisive. While titanium alloys and nickel-based superalloys remain dominant due to their high temperature capability and resistance to corrosive environments, significant R&D is underway into next-generation materials. These include new grades of intermetallic compounds, titanium-aluminides, and powder-forged variants with tailored microstructure for enhanced fatigue life. According to Prof. Linda Zhang of the University of Michigan’s Department of Aerospace Engineering, “Novel alloy development is fundamentally altering the limits of engine performance and service interval, but every new material must be matched by an equally advanced forging route, requiring substantial capital and know-how.” Consequently, leading forging companies are beefing up their partnerships with research labs and universities to stay ahead in the materials arms race.
https://pmarketresearch.com/auto/hybrid-cross-car-beam-market/
Geographically, the aircraft engine forging business remains concentrated in North America and Western Europe, due to the proximity of engine OEMs like GE Aerospace, Rolls-Royce, Pratt & Whitney, and Safran Aircraft Engines. However, Asian manufacturers—especially in China and India—are rapidly scaling up their forging capacity to meet domestic jet assembly needs and to supply global platforms. S&P Global data indicates that China’s aviation forging output will reach 16% of the total global volume in 2025, up from just 8% a decade ago. This expansion is being catalyzed by aggressive government support for indigenous aerospace projects such as the CJ-1000A engine for the COMAC C919.
Expert viewpoints converge on the reality that vendor consolidation, technological specialization, and deeper vertical integration will characterize the competitive landscape in 2025. “We’re seeing a pattern where smaller forgers are either merging or being acquired by larger groups,” says Alex Durand, Managing Partner at AeroMarkets Consulting. “OEMs prefer to deal with fewer, more capable strategic suppliers who can deliver on quality and compliance for highly regulated products.” Major players such as Arconic, Precision Castparts Corp, VSMPO-AVISMA, and Bharat Forge are expanding their technology portfolios and entering into joint ventures to secure access to emerging markets and proprietary processes.
Another crucial trend is the expansion of aftermarket demand. With airline operators increasingly opting for power-by-the-hour contracts and focusing on engine health management, the need for high-quality forged spare parts and repair solutions is surging. This secondary market is becoming an important revenue stream for forging companies that can deliver precision remanufacturing, rapid prototyping, and even custom alloy development for challenging MRO environments.
Worldwide EDTA Tubes Market Research Report 2025, Forecast to 2031
Supply chain resilience is a prominent concern. The disruptions unleashed by the COVID-19 pandemic from 2020 to 2022 exposed vulnerabilities in global sourcing of critical alloys and machining services. In response, forging companies are localizing operations, building multi-site redundancies, and collaborating with logistics providers to ensure stable flows of raw materials and semi-finished forgings. Experts at Deloitte’s Aerospace & Defense practice believe that “the coming years will be defined by continuous supply chain agility, where geographic flexibility and dual/multi-sourcing contracts will be the norm for mission-critical components.”
Worldwide Insulation Testers Market Research Report 2025, Forecast to 2031
Digitalization remains a dominant theme in manufacturing transformation. Enterprise resource planning (ERP) suites, Internet of Things (IoT) sensors, and blockchain-based traceability systems are being applied not only in forging workshops, but across the entire product lifecycle—from engineering design to customer delivery. The integration of quality data, performance feedback, and predictive analytics is helping forging suppliers anticipate defects, improve traceability, and reduce warranty exposures for OEM clients.
The competitive environment is continuing to heat up as new market entrants seek to differentiate on technological prowess or ultra-specialization. For instance, smaller European firms are targeting niche applications within engine subassemblies, such as those required for hybrid-electric propulsion systems and auxiliary power units (APUs), which have distinct performance envelopes compared to conventional jet engines. Meanwhile, Japanese and Korean forging houses are leveraging unique metallurgy capabilities to win contracts for ultra-high strength shaft forgings used in business jet and helicopter engines.
Labor market dynamics and workforce expertise also matter. While the industry is investing heavily in process automation, expert forging technicians and metallurgists remain in high demand, particularly for new product introduction (NPI) programs. This has led to increased partnerships with technical institutes and specialized hiring campaigns, especially in regions where forging expertise historically lags overall aerospace capability growth. Upskilling employees in advanced computer-aided forging simulation, robotic cell management, and AI-based quality assurance are recognized as central to maintaining competitiveness.
Throughout 2025, government and regulatory mandates have impacted forging market trends. The proliferation of safety and environmental standards—such as stricter REACH regulations on high-chromium alloys and the need to certify new manufacturing methods—places additional compliance burdens on forging houses. Yet, many forgers see these regulations as pathways to differentiate and capture premium pricing for certified green products. As noted by Peter Leahy, an independent sustainability consultant: “Forging is at the strategic crossroads; those who move early on compliance and greener processes gain brand equity and stronger ties with progressive airlines and engine makers.”
Looking at the role of automation, robotic forges and automated material handling have been rolled out at high-volume sites operated by industry giants such as Allegheny Technologies and Otto Fuchs. These systems not only improve throughput, but drastically lower workplace accidents and variability in product quality. Advanced non-destructive testing (NDT) techniques—like ultrasonic phased-array and magnetic resonance imaging—are being built into forging lines, providing real-time defect identification and minimizing costly post-process inspections.
The continual rise of additive manufacturing, or 3D printing, is another factor influencing forging industry trajectories. While additive is not expected to fully replace forging for large, high-load components, hybrid manufacturing approaches are gaining traction. “Designers now often combine forged blanks with additive overlays to produce unique cooling channels and weight-optimized geometries impossible with forging alone,” explains Dr. Sandeep Menon, Lead Process Engineer at Safran. This shift is allowing forging suppliers to capture value in new assemblies and facilitate shorter lead times for custom orders.
Investment patterns in 2025 show a tilt towards capacity expansion in digital, sustainable forging and strategic partnerships for global reach. For instance, Arconic recently announced a joint venture in Brazil’s Aerotec Valley targeting low-emission, closed-die forging for regional jet engines. Similarly, VSMPO-AVISMA’s partnership with China’s AVIC Group aims to localize supply of titanium engine forgings for regional and domestic airframes, underscoring the internationalization of forging know-how.
The push for sustainability is also contributing to increased interest in lifecycle analysis and circular economy frameworks. OEMs are requesting forgers to document their environmental footprint, track material utilization, and identify reuse pathways for offcuts and scrap. As airlines and engine makers strive to align with global net-zero initiatives, forging houses are building expertise in reclaiming and repurposing metals—a process that requires new melting and purification technologies to maintain aerospace-grade quality.
https://pmarketresearch.com/hc/cut-stack-product-labels-market/
Forecasts for the remainder of the decade estimate that aircraft engine forging will maintain steady growth, buttressed by the global expansion of air fleets—in Asia-Pacific, Africa, and the Middle East—as well as the replacement of aging propulsion systems with more fuel-efficient models. However, the looming challenges include fierce competition, material volatility, trade protectionism, and the ongoing quest for breakthrough manufacturing processes. Only those companies with the agility to innovate, invest, and align their operations with sustainable goals will be able to capture market share.
With engine architectures advancing—from geared turbofan and open rotor designs to hybrid-electric concepts—the need for finely tunable, reliable forged parts is only set to increase. As this market research reveals, 2025 represents both a test and an opportunity for the aircraft engine forging ecosystem. Through bold innovation, regulatory adaptation, and collaborative ventures, industry leaders are redefining the possibilities for aviation propulsion—making forgings not just strong, but smart, sustainable, and central to the future of flight.
https://pmarketresearch.com/chemi/commercial-aircraft-engine-forging-market/
Contact Information:
Lacy Lee
Senior Marketing Manager [email protected] 00852-95632430
Tags:
CE, Go Media, Go Media2, iCN Internal Distribution, Reportedtimes, Research Newswire, English