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Market Overview
According to Fortune Business Insights, the global aircraft exhaust system market size was valued at USD 1.22 billion in 2024. The market is projected to grow from USD 1.5 billion in 2025 to USD 6.41 billion by 2032, exhibiting a CAGR of 8.34% during the forecast period.
The market covers turbine and piston platforms, spanning engine and APU exhaust assemblies, nozzles, mixers, chevrons, liners, and ducts. Demand is anchored by high fleet utilization accelerating hot-section wear, deep OEM backlogs securing multi-year line-fit volumes, and tightening noise/emissions rules rewarding quieter, hotter-capable architectures.
Major Players Profiled in the Market Report:
Doncasters (U.K.)
Ducommun (U.S.)
Hellenic Aerospace Industry (Greece)
ITP Aero (Spain)
Magellan Aerospace (Canada)
Nexcelle (U.S.)
Nicrocraft (U.S.)
NORDAM (U.S.)
Safran (France)
Senior Aerospace (U.K.)
Source: https://www.fortunebusinessinsights.com/aircraft-exhaust-system-market-113104
Segments
Commercial Segment Driven by Narrowbody Rate Hikes, Widebody Recovery, and Noise/Emissions Compliance
Based on aircraft type, the market is segmented into commercial, regional jets, business aviation, military fixed-wing, helicopters, and general aviation. The commercial segment captured the largest share in 2024 and is anticipated to dominate with a 52.91% share in 2025. This dominance is driven by surging narrowbody build-rates, long-haul recovery, and the need for advanced mixers and liners to meet sustainability targets.
Civil/Commercial Segment Sustained by Airline/Cargo Utilization and Airport Policies
Based on application, the market is classified into civil/commercial and military. The civil/commercial segment is anticipated to dominate with an 81.18% share in 2025. This is anchored by airline and cargo operations requiring reliability and tighter noise footprints, alongside airport APU restrictions pushing for exhaust improvements.
Turbofan Segment Propelled by Record Single-Aisle Backlogs and High-Temperature Efficiency Upgrades
Based on engine type, the market is classified into turbofan, turboshaft, turboprop, and piston. The turbofan segment is anticipated to dominate with a 69.94% share in 2025, tracking record narrowbody backlogs and steady twin-aisle recovery. High exhaust temperatures favor advanced liners and CMCs.
Engine Exhaust System Segment Leading as it Directly Affects Thrust, Noise, and Thermal Management
Based on system, the market is classified into engine exhaust system and APU exhaust system. The engine exhaust system segment is anticipated to dominate with an 86.48% share in 2025. Efficiency programs reward lighter, hotter-capable ducts and nozzles, increasingly designed for additive manufacture.
Aftermarket Segment Accelerating due to Aging Fleets and MRO Capacity Constraints
Based on end user, the market is classified into aftermarket and OEM. The aftermarket segment is anticipated to dominate with a 53.62% share in 2025, buoyed by aging fleets, high utilization, and heat-cycle fatigue necessitating replacements of liners and tailpipes.
Geographically, the market is studied across North America, Europe, Asia Pacific, and the Rest of the World.
Report Coverage
The report offers:
Major growth drivers, restraining factors, opportunities, and challenges.
Comprehensive insights into regional developments and market shares.
List of major industry players and their strategies.
Detailed segmentation analysis by aircraft type, application, engine type, system, and end user.
The latest industry developments include product launches, partnerships, and contract announcements.
Drivers & Restraints
Fleet Utilisation, OEM Backlogs, and Regulations Create Durable Demand for Hot-End Upgrades
Three forces power demand: high utilization accelerating fatigue in tailpipes and nozzles; deep Airbus/Boeing backlogs locking in line-fit volumes; and ICAO/FAA noise stages pushing airlines toward quieter exhaust geometries. Additionally, fuel prices sustain the payback for drag-reducing upgrades, and digital health monitoring turns exhaust wear into predictable workscopes.
Qualification Cycles, Materials Volatility, and Certification Boundaries to Hamper Market Growth
Aerospace qualification is slow and capital-intensive, with new alloys or AM geometries facing lengthy testing. Materials volatility in nickel superalloys and titanium creates cost spikes. Furthermore, certification boundaries limit rapid PMA penetration, and supply chain bottlenecks in specialized forming and acoustic perforation can delay major programs.
Regional Insights
Asia Pacific Dominates the Global Market Due to Rapid Fleet Additions
Asia Pacific dominated the global market with a share of 32.88% in 2024 (USD 401.70 Million). Demand is propelled by rapid fleet additions, new airport capacity, and strong domestic travel. Emerging MRO clusters in India, Singapore, and China are expanding capabilities, while rising utilization accelerates wear in hot sections.
North America to Reach USD 338.8 Million in 2025
Demand in North America is anchored by a large installed fleet, high utilization, and shop visit surges. Sustainability and airport noise programs are driving retrofits, while business aviation adds dependable aftermarket volume.
Aircraft Exhaust System Market Future Growth:
The market is trending toward lighter, hotter-capable, and quieter flowpaths as airlines chase fuel savings and airports tighten noise limits. There is a shift toward data-driven maintenance, with sensorized EGT probes and predictive analytics influencing shop-visit planning. Technically, the adoption of Ceramic Matrix Composites (CMCs), advanced nickel superalloys, and additive manufacturing is moving from trials to production to unlock complex acoustics and weight reductions. The retrofit market will remain robust as operators upgrade legacy fleets to meet environmental standards.
Competitive Landscape
Due to Stricter Rules, OEM Backlogs, and MRO Surge Favor Certified Exhaust Integrators
Key players like Safran, Nordam, and Senior Aerospace are focusing on certified propulsion integration and hot-section metallurgy. Strategies include risk-sharing with OEMs to secure multi-year volumes, leveraging additive manufacturing for complex parts, and expanding global repair footprints to compress turnaround times for airlines.
Key Industry Development
July 2025: ST Engineering’s Middle River Aerostructure Systems (MRAS) was selected by JetZero to design and manufacture the exhaust nozzle for its all-wing demonstrator.
June 2025: Safran Electronics & Defense and Babcock International Group expanded their partnership across mission systems and aircraft engines.
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