Composite Repair Market

Market Definition

Composite repair refers to the process of restoring damaged composite structures, such as those made from carbon fiber reinforced polymer (CFRP), glass fiber reinforced polymer (GFRP), or aramid fiber composites, to their original or near-original strength and functionality. It employs specialized techniques, including bonded patches, resin infusion, autoclave curing, or out-of-autoclave methods, to ensure structural integrity and long-term performance.

It encompasses cosmetic surface repairs, semi-structural fixes for moderate loads, and full structural repairs for load-bearing components. Composite repair is critical in industries such as aerospace, wind energy, automotive, marine, and oil & gas, where extending the lifespan of high-value assets, ensuring safety, and minimizing downtime are essential operational priorities.

Composite Repair Market Overview

The global composite repair market size was valued at USD 16.63 billion in 2024 and is projected to grow from USD 17.74 billion in 2025 to USD 28.98 billion by 2032, exhibiting a CAGR of 7.10% during the forecast period. Market growth is fueled by advanced resin formulations that enhance curing speed, thermal stability, and durability, along with out-of-autoclave processes that reduce energy use and costs. It enables widespread adoption across diverse industrial applications.

The global expansion of wind energy capacity is influencing the market. Turbine blades, primarily made of composites, frequently encounter erosion, lightning strikes, and material fatigue, affecting operational efficiency. The deployment of larger onshore and offshore turbines has increased maintenance complexity.

Key Highlights:

1. The composite repair industry was recorded at USD 16.63 billion in 2024.
2. The market is projected to grow at a CAGR of 7.10% from 2025 to 2032.
3. Asia Pacific held a share of 33.49% in 2024, valued at USD 5.57 billion.
4. The structural segment garnered USD 6.39 billion in revenue in 2024.
5. The hand lay-up segment is expected to reach USD 9.54 billion by 2032.
6. The glass-fibre reinforced polymer (GFRP) segment is anticipated to witness the fastest CAGR of 7.63% over the forecast period.
7. The aerospace & defense segment is estimated to hold a share of 24.18% by 2032.
8. North America is anticipated to grow at a CAGR of 7.29% through the projection period.

Major companies operating in the composite repair market are Lufthansa Technik AG, The Boeing Company, Henkel AG & Co. KGaA, TEAM, Inc., 3M, Belzona International Ltd, Crawford Composites, LLC, Diab Group, HAECO Group, Hexcel Corporation, T.D. Williamson, LLC, MODEC, Inc., Airbus SAS, WichiTech Industries, Inc., and KVE Composites B.V.

Solutions such as in-situ repair kits, vacuum-assisted resin infusion, and specialized surface protection coatings can address these challenges. Aligning advanced repair technologies with the growing renewable energy sector is key to ensuring sustainable and reliable power generation.

• For instance, in April 2025, the Global Wind Energy Council (GWEC) reported a record 117 GW of new global wind capacity installed in 2024 and projected nearly 1 TW of additional installations by 2030.

Market Driver

Rising Demand for Lightweight and Durable Automotive Materials

The composite repair market is witnessing substantial growth, fueled by the automotive industry's growing use of composite materials to meet stringent fuel efficiency and emissions regulations and enhance performance in electric and premium vehicles. Lightweight composites reduce vehicle weight while maintaining structural strength and crash safety, creating a strong demand for composite repair solutions. 

Manufacturers and service providers seek effective methods to restore damaged components, including body panels, structural parts, and interior reinforcements. Composite repair offers a cost-effective alternative to part replacement, promoting sustainability and affordability across the automotive value chain. This underscores the need for scalable, quick, and certified repair techniques to support automotive innovation and customer satisfaction.

• In March 2025, McLaren introduced its Automated Rapid Tape (ART) carbon, introducing aerospace-grade carbon fibre to supercars. This breakthrough advanced lightweight engineering and significantly enhanced the performance potential of future McLaren models.

Market Challenge

High Certification and Qualification Costs

A significant challenge restraining the expansion of the composite repair market is the high cost associated with certification and qualification. Repair processes in aerospace, oil & gas, and marine sectors must meet rigorous standards such as FAA, EASA, ABS, or ASME, which demand extensive testing, validation, and compliance audits. While these regulations ensure safety and reliability, they pose barriers for smaller market entrants.

To overcome this challenge, market players are priortizing strategic partnerships with OEMs, joint development of repair manuals, and investment in standardized materials and automated processes to accelerate approvals. By pooling resources and aligning with regulatory bodies, market players are streamlining certifications and reducing costs.

Market Trend

Integration of Digital Inspection Tools and Predictive Analytics

The integration of digital inspection technologies and predictive analytics is influencing the composite repair market. Advanced tools such as drones, 3D scanners, and ultrasonic devices enable faster and more precise detection of structural defects in composite assets. 

When combined with predictive analytics, these inspections allow operators to forecast damage progression, prioritize maintenance schedules, and reduce costly unplanned downtime. This shift from reactive to proactive repairs enhances operational efficiency and minimizes asset failure risks. 

Digitalization supports data-driven decision-making, enabling service providers to deliver targeted, reliable, and cost-effective repair solutions while strengthening customer confidence and long-term asset management strategies.

• In November 2023, Dassault Systèmes, in collaboration with MEMKO and UniSQ’s iLAuNCH Trailblazer program, enhanced Australia’s sovereign space manufacturing by implementing virtual twin workflows for composite components, bolstering national capabilities in aircraft and spacecraft production and maintenance.

Composite Repair Market Report Snapshot

Market Segmentation

• By Type (Structural, Semi-Structural, and Cosmetic): The structural segment captured the largest share of 38.45% in 2024, mainly due to its critical role in restoring load-bearing aerospace and wind components where safety and performance cannot be compromised.
• By Process (Hand Lay-up, Vacuum Infusion, Autoclave, and Others): The vacuum infusion segment is poised to record a CAGR of 7.40% through the forecast period, owing to its ability to deliver defect-free repairs with consistent resin distribution and cost efficiency.
• By Material (Carbon-fibre Reinforced Polymer (CFRP), Glass-fibre Reinforced Polymer (GFRP), Aramid-fibre Composites, Hybrid, and Others): The carbon-fibre reinforced polymer (CFRP) held a share of 28.08% in 2024, fueled by its superior strength-to-weight ratio, high fatigue resistance, and widespread use in aerospace and automotive applications.
• By End Use (Aerospace & Defense, Wind Energy, Automotive, Marine, Construction, and Others): The marine segment is anticipated to grow at a CAGR of 7.38% over the forecast period, propelled by increasing demand for corrosion-resistant composite repairs in ships, offshore platforms, and marine structures.

Composite Repair Market Regional Analysis

Based on region, the market has been classified into North America, Europe, Asia Pacific, Middle East & Africa, and South America.

The Asia-Pacific composite repair market accounted for a share of 33.49%, valued at USD 5.57 billion in 2024. This dominance is reinforced by the rapid expansion of aerospace manufacturing hubs, large-scale wind energy projects, and extensive composite use in infrastructure and transportation. Regional focus on localized repair facilities supports large turbine fleets and high composite adoption in automobiles and marine vessels. 

Furthermore, government-backed infrastructure projects and investments in offshore wind farms are boosting demand for cost-efficient, scalable repair solutions. With its vast industrial base and strong emphasis on renewable energy, Asia-Pacific is expected to remain a leading market for composite repair solutions.

The North America composite repair industry is projected to grow at the highest CAGR of 7.29% over the forecast years. This growth is primarily supported by the established MRO facilities, large aerospace fleets requiring certified structural repairs, and advanced oil and gas pipeline networks adopting composite overwrap solutions. 

The region also leads in technology adoption, leveraging predictive maintenance tools and digital inspection systems to enhance repair efficiency. Additionally, expanding offshore wind projects highlight the need for blade maintenance services, supporting regional market expansion.

• In October 2024, Hexcel leveraged its expertise in compression molding, out-of-autoclave methods, and accelerated autoclave curing to meet surging demand for high-rate composite manufacturing, driven by next-generation single-aisle aircraft and Advanced Air Mobility electric aircraft.

Regulatory Frameworks

• In the U.S., the Federal Aviation Administration (FAA Part 43 – Maintenance, Preventive Maintenance, Rebuilding, and Alteration) regulates composite repair procedures for aircraft. It ensures certified methods maintain flight safety and airworthiness.
• In the EU, the European Union Aviation Safety Agency (EASA Part 145 – Maintenance Organization Approvals) oversees composite repair activities. It mandates approved organizations and qualified personnel to perform critical repairs under stringent safety protocols.
• In the UK, the UK Civil Aviation Authority (CAP 562 – Civil Aircraft Airworthiness Information and Procedures) sets standards for composite repairs. It provides technical guidance for repairing structural composites in civil aviation fleets.
• In China, the Civil Aviation Administration of China (CCAR-145 – Maintenance Regulations) regulates composite repair operations in aerospace. It aligns with international standards to ensure safety and compliance amid rapid aviation growth.

Competitive Landscape

Key players operating in the composite repair industry are prioritizing strategies that combine innovation, certification alignment, and operational scale. Significant investment in research and development focuses on faster-curing resins, out-of-autoclave processes, and digital inspection integration to deliver more efficient and precise repairs. 

Companies are expanding partnerships with aerospace manufacturers, energy operators, and infrastructure developers to secure long-term contracts and gain access to regulated markets.

There is a major emphasis on geographic expansion, with repair facilities and service hubs being established in emerging economies to address local demand. Key strategies include maintaining regulatory compliance, securing intellectual property around repair formulations, and building skilled technical teams.

• In December 2024, Diab Group acquired Subsea Composite Solutions AS, strengthening its subsea buoyancy services, integrating complementary expertise, and enabling end-to-end solutions from surface to deepwater. The acquisition aims to expand the company's position as a global subsea buoyancy solution provider and access new customer segments.

Key Companies in Composite Repair Market:

• Lufthansa Technik AG
• The Boeing Company
• Henkel AG & Co. KGaA
• TEAM, Inc.
• 3M
• Belzona International Ltd
• Crawford Composites, LLC
• Diab Group
• HAECO Group
• Hexcel Corporation
• D. Williamson, LLC
• MODEC, Inc.
• Airbus SAS
• WichiTech Industries, Inc.
• KVE Composites B.V.

Recent Developments (M&A/Agreements)

• In October 2024, Philippine Airlines renewed its collaboration with Lufthansa Technik, extending engine maintenance services. This renewal complemented existing agreements covering component support for its Boeing 777 fleet, base maintenance services, and specialized composite repairs through Lufthansa Technik Shenzhen.
• In November 2023, Henkel acquired U.S.-based Critica Infrastructure, a provider of composite maintenance, repair, and overhaul solutions for critical infrastructure, including oil and gas transmission networks and municipal water supply systems.