The United States Structural Core Materials Market was valued at USD 3.72 Billion in 2024 and is projected to reach USD 5.89 Billion by 2030, growing at a Compound Annual Growth Rate (CAGR) of 7.8% during the forecast period (2024–2030). This significant growth is fueled by surging demand from the aerospace, wind energy, and transportation sectors, alongside rapid advancements in recyclable and sustainable core material technologies that support the transition to next-generation lightweight structures.

As industries increasingly prioritize weight reduction for enhanced fuel efficiency, performance, and sustainability, structural core materials have become indispensable. These materials, including foam, honeycomb, and balsa, are the backbone of lightweight composite sandwich structures. In this blog, we profile the Top 10 Companies in the United States Structural Core Materials Industry—specialty chemical firms, advanced material suppliers, and composite pioneers shaping the future of American manufacturing and innovation.

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🔟 1. Hexcel Corporation

Headquarters: Stamford, Connecticut, USA
Key Offering: Carbon Fiber Reinforced Polymers (CFRP), Honeycomb Core Materials (Nomex®, HexWeb®)

Hexcel is a global leader in advanced composites technology, specializing in carbon fibers, reinforcements, prepregs, and honeycomb core materials. Its products are critical for aerospace, defense, and industrial applications, providing exceptional strength-to-weight ratios and durability. The company is a primary supplier to major aerospace OEMs like Boeing and Airbus.

Innovation & Sustainability Initiatives:

• Development of bio-based and recyclable resin systems for composite structures

• Investment in automated manufacturing processes for increased production efficiency

• Strategic focus on next-generation aircraft programs requiring advanced lightweight materials

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9️⃣ 2. Toray Industries, Inc.

Headquarters: Tokyo, Japan (Significant operations in the USA)
Key Offering: TORAYCA® carbon fiber, Advanced Composites, Prepregs

Toray is the world’s largest producer of carbon fiber by volume, with a substantial manufacturing and R&D presence in the United States. Its advanced composite materials are essential for the Boeing 787 Dreamliner and other aerospace platforms, as well as for wind turbine blades and automotive components.

Innovation & Sustainability Initiatives:

• Expansion of carbon fiber production capacity in the U.S. to meet growing demand

• R&D into low-cost carbon fiber manufacturing technologies for mass-market adoption

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8️⃣ 3. Owens Corning

Headquarters: Toledo, Ohio, USA
Key Offering: Fiberglass Reinforcements, Composite Systems

Owens Corning is a leading global producer of glass fiber reinforcements and composite materials used in a wide array of structural applications. Its materials are fundamental in wind energy, transportation, construction, and marine industries, providing corrosion resistance and structural integrity.

Innovation & Sustainability Initiatives:

• Pursuit of circular economy principles with a focus on material recyclability

• Development of high-performance glass fibers for larger, more efficient wind turbine blades

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7️⃣ 4. Plascore, Inc.

Headquarters: Zeeland, Michigan, USA
Key Offering: Aluminum and Aramid Honeycomb Cores, Composite Panels

Plascore is a premier manufacturer of honeycomb core materials used in aerospace, military, marine, and industrial applications. The company specializes in custom-engineered solutions that offer high strength, stiffness, and lightweight properties for demanding environments.

Innovation & Sustainability Initiatives:

• Development of specialized honeycomb cores for unmanned aerial vehicles (UAVs) and satellite systems

• Implementation of lean manufacturing to reduce waste and improve sustainability

Download FREE Sample Report:
United States Structural Core Materials Market – View in Detailed Research Report

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6️⃣ 5. Diab Group (Part of ROCKWOOL International A/S)

Headquarters: DeSoto, Texas, USA (Americas Headquarters)
Key Offering: Divinycell® PVC Foams, ProBalsa™ Wood Cores

Diab is a world-leading supplier of core materials for sandwich composite structures. Its Divinycell foam and ProBalsa wood core products are widely used in marine, wind energy, and transportation applications for their excellent mechanical properties and design flexibility.

Innovation & Sustainability Initiatives:

• Introduction of recycled-content foam products

• Focus on developing core materials for the burgeoning offshore wind market in the U.S.

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5️⃣ 6. 3A Composites Core Materials

Headquarters: Sins, Switzerland (Major operations in the USA)
Key Offering: AIREX® & BALTEK® Balsa Wood Cores, PET & PVC Foams

3A Composites is a global leader in core materials, renowned for its BALTEK balsa wood and AIREX polymer foam products. These materials are critical for building lightweight, strong composites in marine, wind energy, and industrial applications.

Innovation & Sustainability Initiatives:

• Sustainable sourcing and cultivation of balsa wood in Equador

• Development of recyclable PET foam solutions as sustainable alternatives to traditional cores

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4️⃣ 7. Gurit Holding AG

Headquarters: Wattwil, Switzerland (Significant U.S. market presence)
Key Offering: Structural Core Materials (Balsa, PET, SAN Foams), Kitting Services

Gurit is a well-established supplier of composite materials, engineering services, and tooling, with a strong focus on the wind energy and marine markets. The company provides integrated material solutions that optimize the manufacturing of large composite structures like wind turbine blades.

Innovation & Sustainability Initiatives:

• Investment in thermoplastic composite technologies for recyclable wind turbine blades

• Expansion of kitting and logistics services to support North American wind energy projects

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3️⃣ 8. Evonik Industries AG

Headquarters: Essen, Germany (Key manufacturing in the USA)
Key Offering: ROHACELL® Polymethacrylimide (PMI) Rigid Foam Cores

Evonik is a leading producer of high-performance ROHACELL PMI foam cores, which are essential for the aerospace, automotive, and medical industries. These foams can withstand high temperatures and offer excellent mechanical properties, making them ideal for primary aircraft structures.

Innovation & Sustainability Initiatives:

• Development of flame-retardant and high-temperature stable foam grades for aerospace interiors

• Research into sustainable feedstocks for advanced polymer production

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2️⃣ 9. BASF SE

Headquarters: Ludwigshafen, Germany (Major production facilities in the USA)
Key Offering: Elastomeric Foams, Engineering Plastics, Polyurethane Systems

BASF offers a comprehensive portfolio of materials that serve as cores or components in composite structures. Its expertise in polyurethane and engineering plastics provides solutions for lightweighting across automotive, construction, and consumer goods sectors.

Innovation & Sustainability Initiatives:

• Advancement of bio-based and recycled content in its material solutions

• Collaboration with automotive OEMs to develop lightweight composite parts for electric vehicles

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1️⃣ 10. The Gill Corporation

Headquarters: El Monte, California, USA
Key Offering: Fiberglass Reinforced Plastic (FRP) Panels, Honeycomb Cores, Composite Structures

The Gill Corporation is a U.S.-based manufacturer specializing in advanced composite materials and finished structures for aerospace, defense, and industrial markets. The company is known for its high-quality honeycomb cores and custom-engineered composite solutions.

Innovation & Sustainability Initiatives:

• Manufacturing of complex composite parts for military aircraft and ground vehicles

• Implementation of advanced Non-Destructive Inspection (NDI) techniques for quality assurance

Get Full Report Here:
United States Structural Core Materials Market – View in Detailed Research Report

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🏗️ Outlook: The Future of Structural Core Materials Is Lighter and Smarter

The structural core materials market is undergoing a profound transformation. While traditional materials continue to serve critical applications, the industry is intensely focused on developing sustainable, high-performance alternatives that meet the demanding requirements of modern engineering and environmental standards.

📈 Key Trends Shaping the Market:

• Accelerated adoption of recyclable thermoplastics and bio-based core materials

• Growing demand from the offshore wind energy sector, particularly along the U.S. coastline

• Increased use of composites in electric vehicle (EV) platforms for battery enclosures and body panels

• Advancements in digital manufacturing and automation for composite part production

Get Full Report Here:
United States Structural Core Materials Market – View in Detailed Research Report

The companies listed above are not only supplying essential materials—they’re building the foundation for a lighter, stronger, and more sustainable future across American industry.