Aerospace 3D Printing Market Size, Share & Industry Analysis, By Vertical (Printers and Materials), By Materials (Metal, Composite, and Polymers (Plastic)), By Platform (UAV, Aircraft, and Spacecraft), By Application (Engine Component, Space Component, and Structural Component), By Printer Technology (Direct Metal Laser Sintering (DMLS), Fused Deposition Modeling (FDM), Continuous Liquid Interface Production (CLIP), Stereolithography (SLA), Selective Laser Sintering (SLS), and Others), and Regional Forecast, 2025-2032

The global aerospace 3D printing market size was valued at USD 3.53 billion in 2024. It is projected to grow from USD 4.04 billion in 2025 to USD 14.53 billion by 2032, exhibiting a CAGR of 20.1% during the forecast period. North America dominated the aerospace 3D printing market with a market share of 34.84% in 2024.

The aerospace 3D printing market is growing significantly due to increased demand for lightweight components that improve fuel efficiency and reduce operational costs. The aerospace industry is increasing the adoption of additive manufactured components in its systems. Companies are using 3D printing technology to create complex shapes that are simple and have the strength and reliability needed for air and space. Market growth is attributed to the growing need to optimize production processes, reduce waste, and enable the production of spare parts based on needs. These developments are crucial, given the complexity and high standards of the aerospace sector.

Key players such as Aerojet Rocketdyne Holdings, Inc., 3D SYSTEMS, INC., and others are focused on research and development to improve 3D printing technologies and actively innovating solutions to enhance system efficiency and expand their global presence. These factors position the market for continued growth in the coming years.  

For instance, in September 2023, the U.S. Air Force awarded a contract worth USD 10.8 million to 3D Systems to supply a Large-format Metal 3D Printer Advanced Technology Demonstrator. The contract supports the advancement of large-scale hypersonic-relevant additive manufacturing print abilities.

Additionally, technological advancements, particularly in the material and printing process, enhance efficiency and make the system lightweight. Strategic partnerships and mergers aim to improve product efficiency and quality, thus fueling market growth and making the system more efficient and reliable.

Market Dynamics

Market Drivers

Growing Demand for Lightweight Components to Enhance Fuel Efficiency in the Aerospace Industry Drives Market Growth

The aerospace industry is increasingly focusing on developing and manufacturing lightweight components for aerospace vehicles such as UAVs, rockets, space shuttles, launch vehicles, and others to maximize their fuel efficiency, as conventional components are extensively heavy, which results in increased drag and fuel consumption.

However, reducing the weight and achieving increased fuel efficiency also affects the average operating cost of aerospace vehicles, as fuel costs comprise 30% of the total costs of airline operations. Aerospace companies regularly face challenges in maintaining their spare parts inventory. As a solution, 3D printing allows the on-demand manufacturing of spare parts, mostly in cases where manufacturing is time-consuming and complex. Additionally, 3D printing is used to manufacture aerospace components, producing physical prototypes that are important for design evaluation and aerodynamic testing.

For instance, in January 2025, Nikon SLM reported that the aerospace industry is no outsider to cutting-edge tech, but additive manufacturing (AM) is taking innovation to supersonic levels. Airbus, with help from Nikon SLM Solutions, has transformed its A330 fuel system components, consolidating over 30 parts into one lightweight component and slashing weight by 75% to improve overall fuel efficiency.

Advancements in Materials and Printing Processes Significantly Contribute to Market Growth 

Technological advancements in aerospace 3D printing processes, such as automation, continuous liquid interface production (CLIP), light-assisted printing, direct metal laser sintering, and other sophisticated techniques, result in faster printing speed. These advancements not only speed up production but also enhance the precision and complexity of printed objects, allowing the attainment of more refined designs and reliable outputs in various aerospace sectors. Moreover, companies are focusing on AI-powered 3D printing solutions to increase the printing efficiency of component design. These factors further propel the aerospace 3D printing market growth.

For instance, in January 2025, the American Center for Manufacturing & Innovation (ACMI) awarded Supernova Industries Corp. a contract worth USD 2 million to supply 3D printing military energetic materials. Through this program, Supernova’s new VLM processing techniques will enable enhanced safety, ensure material consistency, reduce the waste stream, and unlock new performance capabilities for applications such as solid rocket motors, bullet grains, countermeasure flares, or bombs. 

Market Restraints

High Initial Cost of Setting up 3D Printing Systems Limits the Market Growth

The initial cost of setting up advanced 3D printing systems is significantly high. This investment includes the price of the machinery as well as potential expenses for installation, training, and maintenance. For smaller companies, these costs can be substantially high and risky, especially companies that are in the early stages of adopting new technologies.

Moreover, designing certain features requires advanced knowledge of 3D modeling and printing techniques and trained personnel to handle this system, which can incur higher investment needs and hinder the firm's budget. In addition, aerospace 3D printed parts or assemblies often require post-processing, such as sanding, polishing, or painting, to achieve the desired finish and quality. This additional step can add to the overall production time and cost, thus impacting the market growth.    

Supply Chain Limitations Hinder the Market Development

Different types of materials are available for 3D printing in the aerospace sector, including advanced composites and specialized metals. However, a limited supply of raw materials still exists, which hinders systems application, especially in high-performance situations. Moreover, post-processing steps are frequently required to improve the properties of printed parts, complicating the manufacturing workflow and potentially decreasing the time and cost advantages associated with 3D printing. Addressing these material limitations is crucial for the broader integration of 3D printing technology in aerospace applications.

For instance, 3D printer prices range from about USD 200 to USD 500,000+, depending on the printing process, materials, and sophistication of the 3D printing solution.    

Market Opportunities

Integration of AI in 3D Printing Systems to Increase Efficiency and Reduce Human Error Provides a New Market Opportunity

Artificial Intelligence (AI) and Machine Learning (ML) can help analyze large amounts of data and generate improved designs that outdated engineering processes may not be able to achieve. In aerospace, this technology can help create lightweight components that are capable of maintaining structural integrity crucial for fuel efficiency and performance. CAD design tools powered by AI can suggest complex geometries that are often difficult to generate manually.

Moreover, AI aids in the automation of 3D printing processes, including calibration and printer setup, real-time print quality monitoring, and adjustments during the production process. Automating these steps reduces the chance of human error and improves overall efficiency. In addition, AI can help select the best materials for specific applications by analyzing performance data, costs, and availability. This capability can lead to innovations in the types of materials used for 3D printing, such as advanced composites and metals.

For instance, in November 2023, 1000 Kelvin, a start-up based in Germany and the U.S., announced the full commercial availability of its AI-driven software AMAIZE at Formnext 2023. AMAIZE software optimizes print recipes using physics-informed artificial intelligence technology for first-time-right 3D printing (3DP).

Aerospace 3D Printing Market Trends

Integration of 3D Printing in Several Sectors to Fuel the Market Revenue

The adoption of 3D printing technology has increased in various industries, especially in aerospace, for applications in aviation, space exploration, and unmanned aerial vehicles (UAVs). The ability to quickly design, prototype, and manufacture complex parts has propelled the advancements within these sectors.

In the aviation industry, 3D printing is increasingly being used to produce lightweight components. This helps companies provide improved fuel-efficient aircraft and reduce emissions. For instance, Boeing has included 3D-printed parts in its commercial aircraft. They have successfully produced over 60,000 parts using additive manufacturing, with components ranging from engine brackets to cabin components.

In the space exploration sector, 3D printing is invaluable for many government and private space firms. For instance, in October 2020, NASA focused on advancing 3D printing construction systems for the Moon and Mars. Further, in December 2022, NASA awarded an ICON contract worth USD 57 million to develop 3D-printing technology that could aid in building roads, launching pads, and homes on the moon’s surface. 

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SEGMENTATION ANALYSIS

By Vertical

Growing Demand for 3D Printed Components in Aviation, Space, and UAVs Led the Printer Segment Growth

The market is segmented into printers and materials based on the vertical. The printer segment dominated the market in 2024, driven by the increasing adoption of 3D printing technology in the aerospace sector. The aerospace sector has experienced robust growth in the 3D printing market due to the increasing demand for 3D-printed components in aviation, space, and UAVs to make systems lightweight and fuel-efficient, resulting in the adoption of 3D printers in the market to capture the maximum share.   

For instance, in April 2025, Formlabs, a 3D printing company, launched its new printer commercial application. The Formlab’s USD 4,500 Form 4 printer is being used at Microsoft, Ford, NASA, and dentists' offices.

The material segment is anticipated to grow at the highest CAGR during the forecast period. Innovation in materials has resulted in lighter materials with increased strength and durability, which fuels demand in the aerospace market to achieve maximum takeoff weight (MTOW) and flight endurance. Moreover, limited supply chain constraints result in new entrains to solve this challenge and provide materials on demand, further fueling the market growth.    

By Materials

Growing Demand for Metals to Design and Manufacture Different Components in the Aerospace Sector Contributes to the Segment Growth

The market is segmented into metal, composite, and polymers based on the materials. The metal segment dominates the market. This growth is attributed to increasing demand, particularly in the space sector, as metal 3D printing is in high demand to design and manufacture spacecraft, rockets, and launching vehicle components, such as engine parts, nozzles, and other components, with complex design nature and weight reduction requirements.   

For instance, in February 2025, Supernova Industries Corp, a company focused on additive manufacturing, was recognized for its innovative polymer solutions. It received a USD 2 million subcontract from the American Center for Manufacturing & Innovation (ACMI) for its unique Viscous Lithography Manufacturing (VLM) process.

The composite segment is also experiencing robust growth as the adoption of composite, particularly in the aviation and UAV sectors, is increasing. In aviation and UAVs, 3D-printed parts are mostly used in cabin interiors and frame assemblies, respectively. Most quadcopters and other multi-rotor drones use 3D-printed polymer frames and hubs to mount the avionics and other components, resulting in robust growth in this segment.

By Platform

Cost Effectiveness and Reduced Aircraft Emissions Capabilities of 3D Printed Parts Contributed to the Segmental Growth

The market is divided into UAV, aircraft, and spacecraft on the basis of platform. The aircraft segment dominated market growth in 2024, attributed to the increasing adoption of 3D-printed parts and assemblies in the aviation industry. 3D-printed parts and assemblies provide advantages such as cost-efficiency and reduced aircraft emissions. For instance, in September 2019, Additive-X estimated that for every kilogram of weight saved on a commercial aircraft, 25 tons of CO2 emission is prevented during its lifetime, resulting in Airbus using 3D printing to reduce aircraft emissions through replacing parts of existing aircraft models with lighter 3D-printed versions.    

The spacecraft segment is anticipated to grow at the highest CAGR from 2025 to 2032. This growth is attributed to increasing space exploration missions and the adoption of 3D-printed parts and assembly into space shuttles, launch vehicles, and satellites. For instance, NASA is testing the space-worthiness of 3D-printed materials for future applications. The SuperDraco engine, which provides launch escape and propulsive-landing thrust for the Dragon V2 passenger-carrying space capsule, is fully 3D printed.

Additionally, in September 2024, SpaceX and Velo3D established a non-exclusive licensing agreement valued at USD 8 million. USD 5 million is designated for licensing Velo3D's metal additive manufacturing technology, while the remaining USD 3 million is allocated for engineering support services. Velo3D's Sapphire printers, which SpaceX is already utilizing, play a crucial role in this partnership.

By Application

Growing Use of 3D Printing Technology to Manufacture Engine Component Due to Its Low Cost Boosted the Segmental Growth

The market for aerospace 3D printing is segmented into engine component, space component, and structural component by application. The engine component segment dominated the global aerospace 3D printing market share in 2024. The growth is attributed to 3D printing, which allows for tailored solutions that meet specific design requirements and performance goals for engine component manufacturing. This is beneficial for racing and high-performance applications where modified solutions are critical.

For instance, in June 2024, EDEN PRAIRIE, Minn. & REHOVOT, Israel & RIGA, Latvia – Stratasys Ltd. formed a partnership with aviation manufacturing innovator AM Craft to synchronize their initiatives aimed at increasing the demand for flight-certified 3D printed components within the aviation sector.

The space component segment is expected to grow at the fastest CAGR, fueled by diverse applications, including rapid prototyping, production of customized parts, weight reduction, and on-demand manufacturing. For instance, Blue Origin used 3D printing to speed up the design of its BE-4 rocket engine, reducing manufacturing time from over a year to just a few months.

By Printer Technology

FDM Printing Technology Led the Market Due to Its Affordability and Accessibility

Printer technology categorizes the market into direct metal laser sintering (DMLS), fused deposition modeling (FDM), continuous liquid interface production (CLIP), stereolithography (SLA), selective laser sintering (SLS), and others.

Among the printer technology, the fused deposition modeling (FDM) segment dominated the market in 2024. Due to several compelling factors, such as FDM printers, they are generally more affordable than other additive manufacturing technologies, including Stereolithography (SLA) or Selective Laser Sintering (SLS). This accessibility makes FDM an attractive option for small businesses, educational institutions, and hobbyists.

For instance, in November 2023, Stratasys introduced its F3300 Fused Deposition Modelling (FDM) 3D printing system. The company has been teasing the launch on its social media channels for several weeks and will formally unveil the new system during a press conference.

Selective Laser Sintering (SLS) was the second-largest dominant segment in 2024. Selective Laser Sintering (SLS) is an additive manufacturing process that utilizes a high-powered laser to fuse powdered materials, typically thermoplastics, into solid structures. This technique is part of the powder bed fusion category of 3D printing and is known for its ability to produce complex geometries with high precision.

For instance, in January 2025, The Indian Institute of Science’s (IISc) Foundation for Science, Innovation, and Development (FSID) unveiled India’s first domestically developed Selective Laser Sintering (SLS) 3D printer named the Apollo 350 SLS.

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Aerospace 3D Printing Market Regional Outlook

The market is segmented by region into North America, Europe, Asia Pacific, Middle East & Africa, and Latin America.

North America

North America Aerospace 3D Printing Market Size, 2024 (USD Billion)

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North America remains the dominant region in the market and accounted for the largest market share in 2024. North America is a significant contributor to the global market, driven by advancements in technology, increasing demand for lightweight components, and a focus on sustainability. The U.S. allocates a substantial portion of its budget to defense spending and ongoing investments in advanced technologies and material innovation. This financial commitment enables the development and procurement of cutting-edge 3D printing systems. Moreover, North America is home to major companies and technology firms, such as Aerojet Rocketdyne Holdings, Inc., 3D SYSTEMS, INC., and others. These companies play a crucial role in innovation and manufacturing aerospace 3D printing, contributing to the region's leadership in the market.

For instance, in November 2024, a newly awarded competitive contract for an additively manufactured part that prevents structural damage to F-15 aircraft reinforces the Defense Logistics Agency’s commitment to collaborating with the military services on 3D printing procurement strategies. The contract is the first of its kind.

Europe

Europe was the second-dominant region in terms of market share in 2024. European regulatory frameworks are increasingly encouraging the use of 3D printing to manufacture lightweight and efficient aerospace structures, aligning with carbon footprint reduction efforts. There is a growing emphasis on sustainable manufacturing practices across Europe, aligning with strict environmental standards in the region. This trend drives innovation in material development and production processes within the aerospace sector.

Asia Pacific

The Asia Pacific region is witnessing the fastest growth in the market. The acceptance of 3D printing in the Asia Pacific aerospace sector is growing rapidly due to its ability to produce complex parts on demand, which enhances manufacturing efficiency and flexibility. Governments emphasize investments in the global market and defense sectors, which fosters the development of advanced manufacturing capabilities. This includes initiatives aimed at enhancing local production capabilities and reducing reliance on imports. Furthermore, the demand for lightweight and fuel-efficient aircraft is driving the need for innovative manufacturing techniques, such as 3D printing, which can create components that significantly reduce the overall weight.

For instance, in January 2025, Toyota backed Japan’s rocket ambitions with a USD 44.3 million investment in Interstellar Technologies as part of its Series F funding round. Interstellar, which already uses 3D printing to manufacture critical rocket components, plans to combine this approach with Toyota.

Latin America

The Latin America region is expected to experience significant growth during the forecast period, supported by an increasing demand for aircraft and aerospace 3D printed components. Brazil remains a powerhouse in aerospace manufacturing, with a growing interest in additive manufacturing technologies.

Middle East & Africa

The Middle East & Africa region is anticipated to experience moderate growth during the forecast period. The growth is attributed to the growing aerospace sector, which is driven by government initiatives and investments in aviation infrastructure in the region. Countries such as UAE and South Africa are leading with strategic plans to enhance their aerospace capabilities. The region faces challenges such as limited local expertise in advanced manufacturing technologies and a need for stronger regulatory frameworks to ensure the safety and efficiency of 3D printing for the aerospace sector.     

COMPETITIVE LANDSCAPE

Key Industry Players

Leading Players Focus on Integrating 3D Printed Parts and Assembly into Aircraft, Spacecraft, and Unmanned Aerial Systems to Increase their Global Presence

The market is characterized by a competitive landscape featuring key players such as Aerojet Rocketdyne Holdings, Inc., 3D SYSTEMS, INC., Materialise NV, MTU Aero Engines AG, Stratasys Ltd., Desktop Metal, Inc. (EXONE), Velo 3D, GE Sweden Holdings AB (Arcam AB), Envisiontec US LLC, EOS GmbH, Höganäs AB, Ultimaker B.V., and Relativity Space. These companies are investing heavily in research and development to optimize their 3D printing capabilities and expand their product offerings. With a focus on continuous improvement and innovation, firms are also developing new materials and technologies to meet the specific demands of the aerospace industry. As a result, the market is characterized by intense competition, driving advancements that could redefine manufacturing processes and elevate the industry to new heights. As demand for advanced aerospace systems grows, developing 3D-printed parts is becoming crucial for companies looking to maintain a competitive edge in the global aerospace 3D marketplace.

LIST OF KEY AEROSPACE 3D PRINTING COMPANIES PROFILED

• Aerojet Rocketdyne Holdings, Inc. (U.S.)


• 3D SYSTEMS, INC. (U.S.)


• Materialise NV (Belgium)


• MTU Aero Engines AG (Germany)


• Stratasys Ltd. (Israel)


• Desktop Metal, Inc. (EXONE) (U.S.)


• Velo 3D (U.S.)


• GE Sweden Holdings AB (Arcam AB) (Sweden)


• Envisiontec US LLC (Germany)


• EOS GmbH (Germany)


• Höganäs AB (Sweden)


• Ultimaker B.V. (Netherlands)


• Relativity Space (U.S.)

KEY INDUSTRY DEVELOPMENTS

• November 2024 - A recently granted competitive contract for a 3D-printed component that protects F-15 aircraft from structural harm highlights the Defense Logistics Agency's dedication to working with military branches on procurement approaches for additive manufacturing. This contract marks a first in this category. The DLA has previously acquired additively manufactured components via exclusive commercial contracts and singular organic contracts, which Department of Defense organic industrial facilities execute.


• November 2024 - Equispheres, Inc., a producer of metal powders located in Canada, revealed a supply agreement with 3D Systems, based in South Carolina, during Formnext 2024. This collaboration allows for the incorporation of Equispheres’ aluminium powder, manufactured in North America, with 3D Systems’ DMP Flex 350 and DMP Factory 350 Laser Beam Powder Bed Fusion (PBF-LB) additive manufacturing systems.


• October 2024 - The U.S. Air Force awarded Beehive Industries a USD 12.4 million contract to produce 3D print military jet engines for unmanned military vehicles. Under this contract, the firm will collaborate with the University of Dayton Research Institute (UDRI) and the Air Force Rapid Sustainment Office, Wright-Patterson Air Force Base, on the development and production of low-cost small expendable turbine (SET) engines. 


• August 2024 - NASA's Marshall Space Flight Center, in partnership with Jacobs Space Exploration Group, has contracted 3DCERAM Sinto for a FLEXMATIC Ceramic Printer C1000. Additionally, 3DCERAM will join NASA as a collaborator, utilizing the printer to create samples for both small and larger components made from innovative materials. These materials will undergo testing in space and other extreme environmental conditions.


• April 2024 - Relativity Space recently revealed that they had obtained a USD 8.7 million contract from the U.S. Air Force Research Laboratory (AFRL) to explore real-time defect detection in additive manufacturing. Throughout a two-year period, the company conducted comprehensive research focused on improving quality control in 3D printing, especially concerning large-scale metal printing.

REPORT COVERAGE

The report provides a detailed analysis of the overview aerospace 3d printing market and focuses on important aspects, such as key players, products, applications, and platforms depending on various countries. Moreover, it offers deep insights into the market trends, competitive landscape, market competition, pricing of Aerospace 3D printing, and market status and highlights key industry developments. In addition, it encompasses several direct and indirect factors that have contributed to the expansion of the global market in recent years.

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Report Scope & Segmentation