Commercial Aircraft Aluminum Castings Market - Global Forecast 2026-2032

The Commercial Aircraft Aluminum Castings Market size was estimated at USD 8.24 billion in 2025 and expected to reach USD 8.98 billion in 2026, at a CAGR of 8.68% to reach USD 14.76 billion by 2032.

The commercial aviation sector continues to rely heavily on aluminum castings for critical aircraft components, underpinned by aluminum’s advantageous balance of low density and high structural integrity. In narrow-body aircraft such as the Airbus A320, aluminum remains the material of choice for engine housings, landing gear assemblies, and structural panels despite advances in composite technologies. This preference stems not only from decades of validated performance but also from aluminum’s superior recyclability, where recycled aluminum can save as much as 95 percent of the energy required to produce virgin metal, reinforcing its appeal within a sustainability-focused industry.

Beyond established use cases in existing fleets, aviation manufacturers are exploring novel alloys and advanced joining techniques to enhance aluminum’s performance. Recent trials demonstrated a 20 percent weight reduction in wing panels through the application of new high-strength alloys and friction stir welding, which eliminates traditional rivet-based assembly to enable greater automation and tighter tolerances. Such developments highlight aluminum’s ongoing relevance as airframers design next-generation single-aisle jets that prioritize both fuel efficiency and production efficiency.

The integration of precision die casting, investment casting, and sand casting processes has further elevated aluminum’s role in aircraft manufacturing. Die casting delivers complex geometries with tight dimensional control, enabling lightweight components that can withstand extreme temperatures and pressures. Meanwhile, investment casting facilitates the production of high-precision parts like turbine casings and bearing housings, ensuring consistent quality across intricate designs. Combined, these processes reinforce aluminum’s position as an indispensable material for modern commercial aircraft, blending cost-effectiveness with engineering excellence.

The commercial aircraft aluminum castings landscape is undergoing a rapid transformation fueled by advancements in material science, digital manufacturing, and sustainability imperatives. Aircraft designers are increasingly challenged to reduce weight while meeting stricter emissions regulations, spurring the development of novel aluminum-lithium and high-temperature aluminum alloys that push the boundaries of performance. These new alloys promise increases in strength-to-weight ratio without sacrificing corrosion resistance, signaling a shift toward materials that can endure more extreme operating environments and longer service cycles.

Concurrently, digital and additive manufacturing techniques are being integrated into traditional casting workflows, allowing engineers to iterate designs with unprecedented speed. By leveraging 3D printing to create sand molds and investment cast cores, manufacturers can produce components with optimized internal structures and reduced material waste. This convergence of digital design and precision casting not only slashes lead times but also opens doors to component geometries that were previously unachievable with conventional tooling.

Sustainability has also emerged as a core driver of innovation. With nearly 95 percent energy savings achievable through aluminum recycling, suppliers are investing in closed-loop systems that reclaim alloy-specific scrap from production lines and retired airframes. Advanced sorting technologies and alloy recovery processes are being scaled up to ensure that high-value aerospace grades can be reused without compromising performance. These initiatives underscore a broader industry commitment to circular manufacturing principles and position aluminum castings as a cornerstone of greener aviation.

Earlier this year, U.S. trade policy shifted significantly when Section 232 tariffs on aluminum were expanded to eliminate country exemptions and raise rates from 10 percent to 25 percent effective March 12, 2025, followed by an increase to 50 percent on June 4, 2025. These measures applied broadly to aluminum articles and derivative products, reflecting concerns over global excess capacity and its potential threat to national security. The expanded tariffs also terminated the product exclusion process, compelling aerospace manufacturers to reassess sourcing strategies in a higher-duty environment.

As a direct consequence, Canadian producers have rerouted more than 100,000 metric tons of primary aluminum exports away from the United States toward Europe, prompting U.S. buyers to increase reliance on aluminum scrap, which carries lower duties. This shift has driven up the U.S. Midwest premium on sheet and extrusion-grade aluminum but still falls short of offsetting the 50 percent duty on primary metal imports. Equally, the elimination of tariff exemptions has created volatility in global aluminum flows, complicating supply chain planning for casting suppliers and Tier 1 aerospace contractors alike.

Major aerospace suppliers have also signaled the cost impact on their operations. On recent earnings calls, RTX disclosed an expected $850 million tariff hit for 2025, while GE Aerospace projected approximately $500 million in additional costs. Both companies are responding through a mix of cost-saving initiatives and pricing adjustments to mitigate the effects of these elevated duties on engines and engine component production. However, a provisional U.S.–EU agreement reached on July 27, 2025, temporarily preserves tariff-free trade for finished aircraft, engines, and parts, offering some relief for OEMs but leaving the fate of peripheral castings and composite components in a state of uncertainty.

The market’s segmentation framework reveals nuanced dynamics that influence demand and manufacturing strategies across five key dimensions. Product type segmentation shows that engine components such as bearing housings, high- and low-pressure compressor casings, oil pump housings, and turbine casings serve as critical areas of innovation, where weight reduction and high-temperature performance are paramount. Flight control components, including actuator housings and bellcranks, demand both precision and strength, while landing gear components-actuators, strut castings, and torque links-require exceptional fatigue resistance. Structural components round out the portfolio, often leveraging large-scale sand casting for complex airframe sections.

Casting process segmentation underscores the complementary roles of die casting, investment casting, and sand casting in achieving the right balance of volume, precision, and material properties. Die casting is favored for high-volume, thin-walled parts; investment casting delivers intricate, high-tolerance components; and sand casting remains the workhorse for sizable, lower-tolerance structures. This interplay shapes capital investments and plant configurations for suppliers aiming to meet diverse aerospace OEM requirements.

Aircraft type segmentation further refines demand patterns. Business jets typically emphasize premium finishes and tailored configurations that leverage high-end alloys, while narrow-body platforms drive the largest volumes, influencing economies of scale. Regional jets often prioritize rapid turnarounds and modular component designs, whereas wide-body programs demand castings with stringent certification processes to meet extended-range and heavy-payload requirements.

End user segmentation-aftermarket versus original equipment manufacturer-creates distinct lifecycle demands: OEMs focus on first-run quality, traceability, and certification, while aftermarket services emphasize refurbishment, reverse engineering, and compatibility across multiple airframe vintages. Finally, material grade segmentation across 2000, 6000, and 7000 series aluminum alloys ensures that each component is matched to its service conditions, balancing attributes such as tensile strength, weldability, machinability, and corrosion resistance.

Across the Americas, a well-established network of aluminum smelters, recyclers, and casting foundries underpins a robust domestic supply chain. The United States hosts multiple Tier 1 aluminum casting facilities that support both OEM production lines and aftermarket MRO operations. However, the recent tariff-driven pivot toward scrap and secondary feedstock has prompted foundries to enhance scrap sorting capabilities and forge closer alliances with domestic recyclers to ensure alloy-grade consistency and duty-advantaged sourcing.

Europe, Middle East, and Africa benefit from proximity to leading aerospace OEMs and research institutions actively developing next-generation alloys, friction stir welding techniques, and digital casting platforms. Regional partnerships secured temporary relief from U.S. duties through the July 2025 U.S.–EU agreement, stabilizing transatlantic production relationships. Meanwhile, Gulf-based MRO hubs and emerging North African foundries are investing in capacity expansion, spurred by growing demand for sustainable aviation practices and a strategic ambition to capture a greater share of global aircraft servicing.

The Asia-Pacific region is experiencing the fastest expansion, driven by surging commercial air traffic and a strategic shift toward local value addition. India has emerged as a focal point for component sourcing, with suppliers such as Hical Technologies scaling up to produce complex casings and structural parts originally dominated by Western foundries. China’s aerospace industry continues to develop indigenous casting capabilities while Southeast Asian nations bolster MRO and OEM facilities to address capacity constraints and mitigate delivery delays. Collectively, the region’s growth trajectory underscores its pivotal role in shaping global aluminum casting supply chains for years to come.

Constellium has positioned itself at the vanguard of alloy innovation and sustainability in aerospace casting, showcasing new alloy formulations capable of delivering weight savings of up to 20 percent and friction stir welded structures that eliminate rivets for streamlined automation. The company’s emphasis on closed-loop scrap recovery and end-of-life recycling strategies enhances its value proposition to OEMs seeking greener supply chains.

Alcoa, with smelting operations spanning Canada and the United States, has adapted its commercial aircraft casting portfolio to navigate evolving tariff regimes. The company rerouted more than 100,000 metric tons of primary aluminum toward non-U.S. markets and intensified its focus on aluminum scrap supply, which carries lower duties, while evaluating the feasibility of reactivating dormant U.S. smelters pending tariff certainty.

Novelis has reinforced strategic partnerships with key aerospace players, extending multi-year agreements with Embraer and thyssenkrupp Aerospace to deliver aircraft-grade plates, sheets, and value-added pre-cut shapes. At the 2025 Paris Air Show, Novelis also presented a Low Carbon Rib-Demonstrator made with up to 90 percent recycled aluminum input, exemplifying its leadership in circular manufacturing and lightweighting solutions.

On the OEM side, RTX and GE Aerospace have publicly disclosed the scale of their exposure to elevated tariffs, expecting a combined impact exceeding $1.3 billion for 2025. Both companies are pursuing cost mitigation measures, including supply chain diversification, selective use of domestic content strategies, and pricing adjustments in successive contract cycles to offset duty-induced inflationary pressures.

Industry leaders should prioritize supply chain diversification by cultivating relationships with regional scrap processors, secondary alloy makers, and alternative casting partners in tariff-exempt jurisdictions. Establishing multi-sourcing strategies can mitigate duty exposure while ensuring access to critical feedstocks and specialized alloys, particularly when primary imports face steep duties under Section 232.

Strategic investment in advanced alloy and joining technologies-such as aluminum-lithium formulations, friction stir welding, and additive-assisted casting-can unlock additional weight reductions and production efficiencies. By integrating digital simulation tools and 3D printing within core casting workflows, organizations can accelerate design iterations, compress time-to-market, and reduce material scrap, aligning with both performance and sustainability objectives.

Engaging proactively with policymakers and industry associations to shape tariff relief programs or secure targeted exemptions for aerospace-grade castings is crucial. Coordinated advocacy efforts, leveraging data on strategic aerospace supply chain dependencies, can help forge agreements similar to the U.S.–EU aerospace tariff pact. Furthermore, forging public-private partnerships to advance recycling infrastructure and alloy recovery technologies will strengthen the resilience of downstream casting operations.

This analysis was underpinned by a rigorous mixed-methods research approach. Primary research comprised in-depth interviews with senior executives at leading casting foundries, OEM procurement managers, and recyclers to capture real-time insights into supply chain challenges, technological priorities, and regulatory impacts. Secondary research drew upon authoritative sources including official trade proclamations, regulatory filings, and peer-reviewed materials science publications to ensure factual accuracy and contextual relevance.

Quantitative data on trade flows, tariff rates, and production volumes were triangulated using publicly available government statistics, industry association reports, and reputable news outlets. Technical assessments of alloy performance and manufacturing innovations were validated against company press releases, patent filings, and field reports from major aerospace exhibitions. All findings were synthesized and peer-reviewed by a cross-functional team of analysts to ensure the robustness of conclusions and actionable validity.

The convergence of advanced aluminum alloys, digital manufacturing, and sustainability imperatives is reshaping the commercial aircraft aluminum castings market. Suppliers like Constellium and Novelis are driving material innovation and circularity, while strategic partnerships and tariff negotiations underscore the sector’s interdependence across geographies. Though increased duties have introduced cost pressures and supply chain complexity, proactive diversification and technological investment can mitigate these risks and sustain the industry’s trajectory toward lighter, greener aircraft.

By aligning alloy choices with component requirements, optimizing casting processes, and engaging in collaborative policy advocacy, stakeholders can reinforce the strategic relevance of aluminum in future airframes. The insights and recommendations presented herein equip industry decision-makers with the clarity and direction needed to seize emerging opportunities, navigate regulatory headwinds, and deliver high-performance, sustainable aircraft for the next generation of air travel.

If you’re ready to access the depth of insights and strategic analysis that can empower your organization to excel in the rapidly evolving aluminum castings landscape, please reach out to Ketan Rohom, Associate Director of Sales & Marketing at 360iResearch. He can guide you through personalized options, answer any queries about our methodologies, and provide a tailored proposal that aligns with your specific information needs.

Don’t miss the opportunity to secure comprehensive market intelligence that will support data-driven decision making and sharpen your competitive edge. Contact Ketan Rohom today to begin the process of acquiring the full Commercial Aircraft Aluminum Castings market research report and position your company at the forefront of industry innovation and growth.