The Global Aerospace Grade Foam Core Materials Market was valued at USD 761 Million in 2025 and is projected to reach USD 1,457 Million by 2034, growing at a Compound Annual Growth Rate (CAGR) of 10.0% during the forecast period (2024–2034). This robust expansion is primarily fueled by the escalating demand for lightweight, fuel-efficient aircraft, the surge in commercial air travel post-pandemic, and the increasing adoption of advanced composite materials in next-generation military and space platforms.

As aircraft manufacturers relentlessly pursue weight reduction to meet stringent emission standards and enhance performance, foam core materials have become indispensable in the construction of sandwich composites. These materials provide the critical high stiffness-to-weight ratio required for structural components, interiors, and assembly parts. In this blog, we profile the Top 10 Companies in the Aerospace Grade Foam Core Materials Industry—specialty chemical giants and composite specialists who are engineering the lightweight backbone of modern aviation.

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🔟 1. 3A Composites Core Materials

Headquarters: Sins, Switzerland
Key Offering: Airex® & Baltek® Foam Cores (PVC, PET)

3A Composites is a global leader in engineered core materials, with its Airex® and Baltek® brands being industry standards for high-performance foam cores. Their products are specified for critical applications in commercial airliners, business jets, and unmanned aerial vehicles (UAVs) due to their excellent mechanical properties and fire, smoke, and toxicity (FST) ratings.

Innovation Focus:

• Development of recyclable PET foam cores

• Tailored solutions for thermoplastic composite sandwich structures

• Global supply chain supporting major aerospace OEMs

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

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9️⃣ 2. Gurit

Headquarters: Wattwil, Switzerland
Key Offering: Corecell® & ProBalsa™ Foam Cores

Gurit is a premier supplier of composite materials to the aerospace sector, renowned for its innovative Corecell® foam series. This styrene-acrylonitrile (SAN) based foam offers superior toughness and performance for primary and secondary aircraft structures. Gurit’s solutions are integral to the manufacturing of wings, fuselages, and rotor blades.

Innovation Focus:

• Specialization in high-performance SAN foams

• Focus on sustainable material lifecycle and end-of-use solutions

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8️⃣ 3. Diab Group

Headquarters: Laholm, Sweden
Key Offering: Divinycell® Foam Cores (PVC, PET)

Diab is a world-leading manufacturer of structural core materials, with its Divinycell® brand being one of the most recognized names in the industry. Their foam cores are used extensively in a wide range of aerospace applications, from interior panels to highly loaded structural components in military aircraft and helicopters.

Innovation Focus:

• High-temperature PVC foams for engine nacelles

• Lightweight PET foam solutions for sustainable aviation

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7️⃣ 4. Evonik Industries AG

Headquarters: Essen, Germany
Key Offering: ROHACELL® PMI Foam Cores

Evonik is the global technology leader in polymethacrylimide (PMI) rigid foams, marketed under the ROHACELL® brand. This material is the preferred core for high-end aerospace and defense applications requiring the highest mechanical properties and thermal stability, making it ideal for primary structures in fighter jets and satellites.

Innovation Focus:

• Ultra-high performance PMI foams for extreme environments

• R&D into functionalized foam cores with integrated sensor capabilities

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

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6️⃣ 5. Armacell

Headquarters: Luxembourg, Luxembourg
Key Offering: ArmaForm® & ArmaCore® PET Foam Cores

Armacell is a key player in the foam core market, specializing in advanced PET (Polyethylene Terephthalate) foams. Their ArmaForm® and ArmaCore® products are 100% recyclable and offer an excellent alternative to traditional PVC foams, gaining significant traction in the aerospace industry for their environmental profile and robust performance.

Innovation Focus:

• Leading the shift towards bio-based and recyclable foam cores

• Solutions for lightweight aircraft interiors and radomes

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5️⃣ 6. General Plastics Manufacturing Company

Headquarters: Tacoma, Washington, USA
Key Offering: LAST-A-FOAM® Polyurethane & Polyisocyanurate Foams

General Plastics is a US-based manufacturer with a long history of supplying rigid foam cores to the aerospace and defense sectors. Their LAST-A-FOAM® series includes a range of polyurethane and polyisocyanurate foams known for their versatility, machinability, and ability to meet specific military and aerospace specifications.

Innovation Focus:

• Custom-formulated foams for specialized defense applications

• Focus on fire-resistant and high-density core materials

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4️⃣ 7. Sekisui Chemical Co., Ltd. (Voltek Division)

Headquarters: Osaka, Japan
Key Offering: Volara® & Minicel® Cross-Linked PE Foams

Sekisui Chemical, through its Voltek division, is a major supplier of cross-linked polyethylene foams. While often used in interior applications for their excellent cushioning and sealing properties, these foams also serve as core materials in non-structural and semi-structural components in aircraft cabins.

Innovation Focus:

• Development of low-smoke, low-toxicity foams for cabin safety

• Lightweight solutions for acoustic and thermal insulation

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3️⃣ 8. Amorim Cork Composites

Headquarters: Santa Maria de Lamas, Portugal
Key Offering: Cork Core Materials

Amorim Cork Composites offers a unique, sustainable alternative to synthetic foams with its agglomerated cork core materials. Cork provides excellent vibration damping, acoustic insulation, and fire resistance, making it a compelling choice for specific aerospace interior and secondary structure applications, particularly as the industry emphasizes natural and renewable materials.

Innovation Focus:

• Pioneering the use of 100% natural and renewable core materials

• Hybrid cork-composite solutions for enhanced performance

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2️⃣ 9. BASF SE

Headquarters: Ludwigshafen, Germany
Key Offering: Elastopor® & Elastocoat® Polyurethane Systems

BASF, a global chemical giant, supplies advanced polyurethane systems that can be formulated into rigid foam cores for aerospace applications. Their expertise in polymer chemistry allows them to develop customized solutions that meet the demanding performance and safety standards of the aviation industry.

Innovation Focus:

• Development of high-performance PU systems for composite cores

• Integration of foam cores into larger lightweighting strategies for OEMs

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1️⃣ 10. Changzhou Tiansheng New Materials Co., Ltd.

Headquarters: Changzhou, China
Key Offering: PVC & PET Foam Cores

Changzhou Tiansheng is a prominent Chinese manufacturer of polymer foams, including a range of aerospace-grade PVC and PET cores. As China’s aerospace industry expands rapidly, domestic suppliers like Tiansheng are playing an increasingly vital role in the regional supply chain, serving both commercial and military aircraft programs.

Innovation Focus:

• Cost-competitive foam cores for the growing Asian aerospace market

• Investment in R&D to meet international quality and performance standards

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

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✈️ Outlook: The Future of Aerospace Foam Cores is Lighter and Smarter

The aerospace foam core materials market is undergoing a significant transformation. While traditional PVC and PMI foams continue to dominate high-performance applications, the industry is increasingly embracing sustainable alternatives like PET and bio-based foams, driven by environmental regulations and lifecycle cost considerations.

📈 Key Trends Shaping the Market:

• Accelerated adoption of recyclable PET foams to meet sustainability targets

• Development of multifunctional cores with integrated thermal/acoustic properties

• Growing demand from the Urban Air Mobility (UAM) and UAV sectors for lightweight solutions

• Increased automation in core machining and composite manufacturing processes

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

The companies listed above are not just supplying materials; they are providing the enabling technology for lighter, more efficient, and more sustainable aircraft, fundamentally shaping the future of flight.