The Global Aerospace Grade Foam Core Materials Market was valued at USD 710 million in 2023 and is projected to reach USD 1,281.6 million by 2030, growing at a Compound Annual Growth Rate (CAGR) of 8.8% during the forecast period (2024-2030). This growth is driven by increasing aircraft production, demand for lightweight materials in modern aircraft design, and the expansion of commercial and military aviation sectors worldwide.

As aircraft manufacturers prioritize weight reduction and fuel efficiency, aerospace-grade foam cores have become critical structural components in wings, fuselages and interior panels. These materials offer exceptional strength-to-weight ratios while meeting stringent fire safety and durability requirements. Below we analyze the Top 10 Companies in the Aerospace Grade Foam Core Materials Market – materials science leaders pushing boundaries in polymer innovations and composite solutions.

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🔟 1. 3A Composites Core Materials

Headquarters: Sins, Switzerland
Key Offering: Airex® and Baltek® foam cores

3A Composites leads the aerospace foam market with its proprietary Airex® thermoplastic and Baltek® structural core material systems. These solutions are extensively used in Airbus, Boeing and military aircraft programs for weight-critical applications.

Advanced Material Properties:

• High-performance PET and PU foam variants
• Closed-cell structures with excellent moisture resistance
• Custom formulations for acoustic and thermal insulation

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Aerospace Grade Foam Core Materials Market – View in Detailed Research Report

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9️⃣ 2. Armacell International S.A.

Headquarters: Luxembourg, Luxembourg
Key Offering: ArmaForm® and Arma-Core® series

Armacell manufactures high-performance structural foam cores used in aircraft flooring, wing ribs and other critical airframe components. Their materials meet demanding flame/smoke/toxicity (FST) standards.

Key Applications:

• Primary and secondary aircraft structures
• Helicopter rotor blade cores
• Space vehicle components

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8️⃣ 3. Evonik Industries AG

Headquarters: Essen, Germany
Key Offering: Rohacell® structural PMI foams

Evonik’s Rohacell® polymethacrylimide (PMI) foams are the gold standard in aerospace sandwich constructions, offering exceptional mechanical properties at ultra-low densities.

Material Advantages:

• Highest specific stiffness in aerospace foams
• Thermal stability up to 180°C continuous service
• Approved for Airbus and Boeing OEM specifications

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7️⃣ 4. Gurit Holding AG

Headquarters: Wattwil, Switzerland
Key Offering: Kerdyn® Green foam cores

Gurit provides advanced structural foam solutions for composite sandwich panels used in commercial jetliners, business aircraft and UAVs. Their Kerdyn® Green product line features sustainable material chemistry.

Technical Features:

• Phenolic foam for superior fire performance
• Bio-based formulations reducing carbon footprint
• Optimized for resin infusion processes

Download FREE Sample Report:
Aerospace Grade Foam Core Materials Market – View in Detailed Research Report

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6️⃣ 5. Diab Group

Headquarters: Laholm, Sweden
Key Offering: Divinycell® structural foams

Diab’s Divinycell® PVC and PET foam cores are widely used in aerospace applications requiring high shear strength and impact resistance combined with minimal weight.

Material Characteristics:

• Excellent fatigue resistance properties
• Low thermal conductivity for insulation
• Compatible with all major resin systems

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5️⃣ 6. General Plastics Manufacturing Company

Headquarters: Tacoma, Washington, USA
Key Offering: LAST-A-FOAM® FR series

As a leading U.S. manufacturer, General Plastics supplies fire-resistant polyurethane and polyisocyanurate foams for military and commercial aerospace applications.

Key Properties:

• Superior compression strength retention
• Exceptional resistance to aviation fuels
• Custom density and formulation options

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4️⃣ 7. CoreLite Inc.

Headquarters: Fenton, Michigan, USA
Key Offering: CoreLite structural foam cores

CoreLite specializes in high-density closed-cell foams for demanding aerospace applications including radomes, fairings and interior components.

Technical Advantages:

• Ultra-low moisture absorption
• Excellent dielectric properties
• Optimized for CNC machining

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3️⃣ 8. Sekisui Chemical Co., Ltd.

Headquarters: Tokyo, Japan
Key Offering: S-LEC cellular PVC foams

Sekisui provides high-performance cellular PVC materials that offer unique combinations of flexibility and durability for aircraft interior applications.

Application Areas:

• Cabin sidewall and ceiling panels
• Aircraft galley components
• Seating structural elements

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2️⃣ 9. Polystrand, Inc.

Headquarters: Englewood, Colorado, USA
Key Offering: Thermoplastic composite cores

Polystrand develops innovative thermoplastic foam core materials suited for repairable and recyclable aircraft structures.

Material Innovation:

• Fully recyclable structural solutions
• Radiation shielding formulations
• Damage-tolerant architectures

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1️⃣ 10. Amorim Cork Composites

Headquarters: Santa Maria da Feira, Portugal
Key Offering: Expandable composite cores

Amorim brings sustainable material solutions to aerospace through cork-based and other natural fiber foam alternatives for secondary structures.

Sustainability Focus:

• Renewable material compositions
• Reduced manufacturing emissions
• End-of-life recyclability

Get Full Report Here:
Aerospace Grade Foam Core Materials Market – View in Detailed Research Report

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✈️ Market Outlook: Lightweight Materials Driving Aviation Innovation

The aerospace foam core market is experiencing transformative growth as new aircraft programs demand advanced materials with superior mechanical properties and sustainability benefits.

📈 Key Industry Trends:

• Accelerating adoption of thermoplastic foam cores for recyclability
• Growing use of hybrid core solutions combining different material types
• Increasing R&D into bio-based foam chemistries
• Digital manufacturing technologies optimizing core material utilization

Get Full Report Here:
Aerospace Grade Foam Core Materials Market – View in Detailed Research Report

The companies profiled here represent the vanguard of aerospace materials science, developing the structural core solutions that enable lighter, more efficient next-generation aircraft designs.