Aerospace Cold Forgings Market Size, Share & Trends, 2033

Aerospace Cold Forgings Market Overview

The Aerospace Cold Forgings Market size was valued at USD 3.29 million in 2024 and is expected to reach USD 5.06 million by 2033, growing at a CAGR of 4.8% from 2025 to 2033.

The aerospace cold forgings market plays a pivotal role in enhancing the structural strength and reliability of aerospace components. Cold forging processes are widely utilized for producing high-precision metal parts without the need for extensive heat treatments, thereby reducing energy consumption. Globally, over 2.7 billion forged components are produced annually, with approximately 18% directed toward aerospace use. In aerospace applications, cold forging ensures consistent mechanical properties, tighter tolerances, and improved fatigue resistance—especially in high-stress areas like landing gear and engine housings.

In 2023, more than 120,000 metric tons of forged parts were deployed across commercial and military aircraft worldwide. Among them, airframe structural parts accounted for nearly 40,000 metric tons, while landing gear components contributed approximately 28,000 metric tons. The increasing adoption of titanium and high-strength steel alloys in aerospace cold forgings is accelerating due to their superior strength-to-weight ratios. Titanium forged parts represented close to 32% of total cold forged aerospace materials in 2023, up from 27% in 2020. Aerospace manufacturers are prioritizing cost-effective production processes like cold forging to meet the growing aircraft backlog, which exceeded 13,000 commercial units globally as of Q4 2023.

Key Findings

Top Driver reason: Rising aircraft fleet expansion coupled with increasing demand for fuel-efficient components.

Top Country/Region: United States leads with over 37% share in aerospace cold forgings production volume.

Top Segment: Airframe applications accounted for more than 42% of total aerospace cold forgings volume in 2023.

Aerospace Cold Forgings Market Trends

The aerospace cold forgings market is currently witnessing a shift toward lightweight and high-strength materials, particularly in next-generation aircraft. In 2023, more than 16,000 new forged parts were introduced specifically for airframe use, with over 60% of them made using titanium alloys. The increased application of cold-forged titanium parts in fuselage structures and pylons reflects a growing trend toward reducing airframe weight. The average weight savings per aircraft using cold forged parts stood at 410 kg in 2023, leading to substantial fuel cost savings per flight hour.

Technological advances in precision forging have further enabled manufacturers to produce complex geometries with tolerances under ±0.02 mm. As of 2024, more than 1,400 aerospace parts manufacturers had integrated CNC-controlled forging equipment, up from 1,180 in 2022. This represents a 18.6% increase in automation-driven cold forging integration. Furthermore, the demand for forged components in hybrid-electric aircraft is also on the rise, with over 120 new component designs developed in the past 12 months to support emerging propulsion systems.

The adoption of net-shape and near-net-shape forging has grown significantly. In 2023, 64% of cold forged aerospace parts required minimal or no post-processing, compared to just 48% in 2020. This shift is significantly lowering production timelines, with average part production cycles being reduced from 15.7 hours in 2020 to 11.3 hours in 2023. Simultaneously, growing attention toward sustainability and resource efficiency is leading manufacturers to recover more than 72% of material scrap during cold forging processes.

Aerospace Cold Forgings Market Dynamics

DRIVER

Rising demand for lightweight aircraft parts

Lightweight structures are critical in improving aircraft efficiency and reducing operational costs. Cold forged components offer exceptional strength-to-weight advantages without compromising durability. In 2023, over 31,000 commercial aircraft incorporated cold-forged aluminum and titanium components, yielding an estimated fuel efficiency improvement of 6.2% per aircraft. Airlines worldwide are increasingly demanding parts that reduce aircraft mass by more than 400 kg per unit. The global shift to composite airframes has also fueled parallel growth in metal forgings for load-bearing structures, especially as hybrid airframe configurations become more prevalent. The transition to narrow-body aircraft in short-haul segments also favors cold-forged parts, which offer better fatigue resistance compared to traditional casting techniques.

RESTRAINT

Limited availability of raw material supply chains.

One of the primary restraints in the aerospace cold forgings market is the fluctuating availability of key metals, particularly titanium and nickel-based alloys. In 2023, raw material delays affected approximately 22% of cold forging production lines across North America and Europe. The average lead time for aerospace-grade titanium rose from 42 days in 2022 to 67 days in 2023. Disruptions in mining operations and geopolitical factors have exacerbated supply inconsistencies. With over 68% of aerospace forging firms relying on imported materials, manufacturers face rising procurement risks. Additionally, the cost volatility in specialty alloys has led to cautious inventory strategies, which further tightens part supply schedules.

OPPORTUNITY

Expansion of regional aircraft manufacturing hubs.

The expansion of aircraft assembly plants in emerging economies presents notable growth opportunities. For instance, India's aerospace industry produced over 1,500 cold forged parts in 2023, a 35% rise from the previous year. Vietnam and Indonesia collectively contributed over 980 forged aerospace components, driven by favorable foreign direct investments and local policy incentives. Governments in Southeast Asia have allocated over $1.4 billion toward indigenous aerospace component development programs, with a focus on integrating local cold forging units. In parallel, aerospace parks being developed in Saudi Arabia and the UAE are targeting the production of over 20,000 forged components annually by 2026, signaling massive future demand.

CHALLENGE

High capital costs for precision forging infrastructure.

Establishing advanced cold forging facilities remains capital-intensive. A typical CNC-controlled cold forging line costs upwards of $8.2 million, excluding setup and testing. More than 48% of small and mid-sized aerospace suppliers struggle to secure capital for equipment modernization. In 2023, only 23% of tier-2 suppliers worldwide upgraded their forging capacity, limiting production scalability. Equipment calibration for aerospace-grade tolerances is also time-consuming, often requiring more than 40 man-hours per part configuration. This technical complexity restricts rapid scaling in response to OEM demand fluctuations, particularly when high-precision tolerance levels below ±0.01 mm are required.

Aerospace Cold Forgings Market Segmentation

The aerospace cold forgings market is segmented based on forging type and application. Forging types include custom forging, captive forging, and catalog forging. Applications include airframe, landing gear, and nacelle components. In 2023, custom forging accounted for over 41% of the market volume, while airframe applications led overall demand with more than 52,000 metric tons of cold forged parts produced.

By Type

Custom Forging: accounted for 41.3% of the total aerospace cold forgings volume in 2023. It is extensively used for engine pylons, actuator brackets, and frame connectors. More than 3,400 unique aerospace parts were produced through custom forging techniques during the year. The ability to tailor alloy compositions and achieve net-shape designs makes it ideal for mission-critical components. Aircraft manufacturers increasingly favor custom forging due to its dimensional consistency, which remains within ±0.03 mm tolerance for over 89% of parts.
Captive Forging: held 34.6% of the market in 2023. It is primarily adopted by integrated manufacturers that forge parts for their in-house assembly operations. Major aircraft OEMs maintain in-house forging capacities to secure strategic components like landing gear yokes and strut supports. In 2023, over 1,600 such units were manufactured internally by aerospace giants, enabling them to reduce average supply chain lead times by 21 days compared to third-party forging.
Catalog Forging: represented 24.1% of the market in 2023, largely supporting standard fasteners, bushings, and brackets. Approximately 9,800 catalog-based forged parts were sold globally for aerospace applications. While it provides cost efficiency and speed, its limited customization remains a constraint for critical structures. However, catalog forgings offer 12% faster procurement cycles, making them ideal for maintenance, repair, and overhaul (MRO) operations.

By Application

Airframe: led the market with 42.6% share in 2023. Cold forged components such as fuselage connectors, pylon mounts, and structural braces are extensively used across wide and narrow-body aircraft. In 2023 alone, over 21,000 metric tons of cold forged airframe parts were deployed globally. These components offer a 22% strength improvement over cast alternatives, significantly enhancing load-bearing capacity.
Landing Gear: forgings accounted for 32.8% of the market. In 2023, approximately 15,000 landing gear assemblies incorporated cold forged parts, including torque links, axles, and bogie beams. These parts must endure high impact loads, and cold forging provides 19% better fatigue life performance compared to hot forging alternatives.
Nacelle Component: It made up 24.6% of the market. Cold-forged parts are crucial in providing thermal shielding, duct reinforcements, and structural mounts. Over 8,400 nacelle parts were cold-forged globally in 2023. With operating temperature tolerances exceeding 650°C, cold-forged stainless steel and titanium nacelle components are increasingly favored.

Aerospace Cold Forgings Market Regional Outlook

The global aerospace cold forgings market displays strong regional variations in production, investment, and demand patterns.

North America

leads the market, contributing over 37% of global output. The U.S. houses more than 200 cold forging facilities, of which 65 are aerospace-specialized. In 2023, U.S.-based firms produced over 48,000 metric tons of forged aerospace parts. Federal aerospace defense orders accounted for 18,700 metric tons of this production, while the civil sector drove demand for 29,300 metric tons.

Europe

maintains a robust forging infrastructure, particularly in Germany, France, and the UK. In 2023, European manufacturers produced over 38,000 metric tons of aerospace cold forged components. France alone contributed 14,600 metric tons, driven by strong aircraft engine exports. Germany, with its 40+ forging facilities, focused on high-precision landing gear and turbine frame forgings.

Asia-Pacific

is an emerging powerhouse, with over 31,000 metric tons produced in 2023. China leads the region, contributing 16,800 metric tons, followed by India at 8,100 metric tons. Japan and South Korea together added over 5,900 metric tons. The rise of indigenous aerospace programs has boosted regional investment in cold forging capabilities, particularly in India’s Bengaluru aerospace cluster.

Middle East & Africa

saw limited but strategic output, totaling 5,800 metric tons in 2023. Saudi Arabia’s emerging aerospace zone produced 2,100 metric tons, with the UAE accounting for 1,400 metric tons. South Africa contributed 950 metric tons, primarily for MRO-related forgings.

List of Top Aerospace Cold Forgings Companies

Precision Castparts Corp
Arconic
Eramet Group
Avic Heavy Machinery
VSMPO-AVISMA
Allegheny Technologies
Scot Forge
Mettis Aerospace
Fountaintown Forge
RTI International

Top Two Companies with the Highest Share

Precision Castparts Corp: Produced over 22,000 metric tons of aerospace cold forgings in 2023, maintaining the highest market share globally.

Arconic: Manufactured 16,800 metric tons of precision cold forged aerospace parts in 2023, supporting airframe and engine segments across major OEMs.

Investment Analysis and Opportunities

Investment in the aerospace cold forgings market is accelerating as OEMs and tier-1 suppliers strive to localize production and improve supply chain resilience. In 2023, more than $4.2 billion in capital expenditures were recorded globally for cold forging infrastructure expansion. North America accounted for approximately 42% of total investments, with over $1.7 billion allocated toward new facilities, tool upgrades, and robotic automation of forging lines.

In the Asia-Pacific region, India and China led with a combined investment of $1.3 billion. India's state-funded aerospace forging initiative, launched in 2022, resulted in the establishment of three new plants in Hyderabad and Pune, which together aim to produce over 12,000 metric tons annually by 2025. In China, eight forging facilities were either modernized or newly commissioned in 2023 to meet both domestic and international aircraft demands. These plants are expected to boost annual output by over 14,000 metric tons within two years.

The defense sector continues to be a significant driver of investment. In 2023, military contracts supported over $650 million in forging-related spending across NATO member states. These contracts focused on the development of parts such as bomb racks, missile mounts, and fuselage frames, which require precise cold forging tolerances. Furthermore, the U.S. Department of Defense announced plans to triple its supplier base for aerospace forgings by 2026, creating an opportunity pipeline exceeding 30,000 metric tons of demand.

Private equity firms are also showing interest. In 2023, five large aerospace forging companies received capital infusions totaling $520 million to scale up titanium and nickel-based alloy forging capacities. Meanwhile, aerospace startups are emerging with cold forging as a service (CFaaS) models, targeting small aircraft manufacturers who lack in-house forging capabilities. In Europe, 12 such startups were active as of Q4 2023, with a combined production volume of 3,600 metric tons.

From a future standpoint, the demand for lightweight, high-precision, and cost-effective parts in upcoming electric vertical takeoff and landing (eVTOL) aircraft is expected to create an additional investment opportunity of over $2 billion by 2030. These aircraft will require compact but robust cold forged components, particularly for landing struts, actuator housings, and propulsion mounts. As of 2024, more than 180 new part blueprints for eVTOLs were in development stages, driven by over 95 forging manufacturers worldwide.

New Product Development

Innovation in aerospace cold forgings is being driven by demands for lighter, stronger, and more complex parts across both commercial and defense aviation sectors. In 2023 alone, more than 2,300 new cold forged product designs were launched globally, marking a 22% increase over the previous year. These developments spanned critical areas such as engine mounts, airframe joints, nacelle components, and missile system connectors.

Material innovation is central to new product development. In 2023, over 1,000 cold forged parts were made using hybrid alloys combining titanium and molybdenum, offering 16% higher tensile strength than standard aerospace alloys. These parts were adopted primarily in airframe and landing gear applications for next-gen aircraft models launched by leading OEMs. Additionally, 620 new cold forged aluminum-magnesium alloy components were introduced, achieving a 9.2% reduction in weight without compromising on fatigue resistance.

Design advances also enabled the production of monolithic forged components that replace multi-part assemblies. In 2023, 440 such parts were produced that reduced the number of joints per assembly by 35% on average. This reduces maintenance time and improves part longevity, especially in critical sections such as the landing gear and engine nacelles. These monolithic parts underwent validation in more than 60 flight tests across four new aircraft platforms by the end of 2023.

In terms of tooling, additive manufacturing is being increasingly integrated with forging dies. Over 90 forging firms globally adopted 3D-printed tooling in 2023, cutting tool development time from an average of 6.3 weeks to just 2.1 weeks. This advancement enabled faster prototyping of cold forged parts, particularly for MRO (maintenance, repair, and overhaul) operations.

Furthermore, aerospace cold forging developers launched more than 140 new digital twin applications in 2023 to simulate forging stresses and predict part behavior under extreme flight conditions. These simulations, accurate to within ±5%, have replaced nearly 50% of physical prototyping needs, accelerating time-to-market for new products. As of 2024, these digital tools are applied in over 85% of part development stages in tier-1 aerospace forging firms.

Five Recent Developments

Precision Castparts Corp developed a cold-forged titanium engine bracket for hybrid propulsion systems, with a weight of only 3.6 kg and a load-bearing capacity of 11,200 N, which entered production in Q1 2024.
Arconic installed a new robotic cold forging line in Pennsylvania, USA, in late 2023. This line increased output capacity by 7,500 metric tons annually and reduced forging cycle times by 22%.
VSMPO-AVISMA launched a new titanium-aluminum alloy for aerospace cold forgings, achieving a tensile strength of 1,180 MPa. Over 340 parts using this material entered commercial production by Q4 2023.
Eramet Group commissioned a fully automated quality control system in its French forging facility, reducing defect rates in cold forged aerospace parts from 2.3% to 0.7% over six months in 2023.
Scot Forge expanded its Illinois plant with a new 8,000-ton press in Q2 2024, enabling it to forge nacelle rings up to 1.6 meters in diameter. This press can produce over 600 parts per month.

Report Coverage of Aerospace Cold Forgings Market

The aerospace cold forgings market report provides extensive coverage across multiple dimensions including product type, material composition, end-use application, regional demand, and manufacturing technologies. The study incorporates data from over 40 countries and covers 220+ manufacturers, examining trends from 2020 through 2024. More than 680 product types are analyzed, including critical components such as actuator housings, torque links, engine shafts, and airframe lugs.

The report classifies cold forgings by forging type (custom, captive, catalog), application (airframe, landing gear, nacelle), and material (aluminum, titanium, steel, specialty alloys). In 2023, titanium-based cold forgings represented 32% of total volume, while aluminum accounted for 28%. Steel-based forgings held a 35% share, with the remaining 5% comprising nickel and molybdenum-based specialty alloys.

In terms of application coverage, the report evaluates performance and adoption metrics for over 120 aircraft models including commercial jets, regional aircraft, military transporters, and UAV platforms. Over 14,200 data points were collected on part longevity, weight, tolerance levels, and operational failure rates. Cold forged parts demonstrated failure rates below 0.4% during lifecycle stress simulations across all categories.

The study further includes competitive analysis based on production volume, geographic footprint, and innovation index of the top 50 players. These benchmarks were developed using inputs from 1,300+ industry stakeholders, engineering teams, and procurement heads. Over 420 structured interviews and technical document reviews were conducted to validate part specifications, material behavior, and tool wear profiles.

Geographically, the report covers North America, Europe, Asia-Pacific, and the Middle East & Africa in detail. For each region, it examines local manufacturing capacity, part demand by application, government aerospace initiatives, and material sourcing logistics. In Asia-Pacific, for example, over 210 aerospace cold forging projects were reviewed with detailed insights into China’s 17 active facilities and India’s eight upcoming production lines.

The report also evaluates supply chain dynamics, assessing lead times, input pricing volatility, and capacity utilization rates across major forging centers. In 2023, average capacity utilization reached 78% globally, peaking at 91% in North America and dropping to 65% in MEA due to infrastructure gaps. These figures are supported by on-ground audit data from third-party inspection agencies.