U.S. Aluminum Forging Market Size, Share & Industry Impact Analysis, By Forging Type (Close Die, Open Die, and Ring Rolled), By End-Use Industry (Aerospace and Defense, Automotive & Transportation, Industrial Machinery, Construction, and Others), and Country Forecast, 2025-2032

The U.S. Aluminum Forging market size was valued at USD 1.38 billion in 2024. The market is projected to grow from USD 1.41 billion in 2025 to USD 1.72 billion by 2032, exhibiting a CAGR of 2.8% during the forecast period.

The U.S. aluminum forging market forms a critical part of the nation’s advanced manufacturing ecosystem, supported by strong domestic demand from aerospace, defense, automotive, industrial machinery, and energy sectors. Aluminum is heavily utilized in transportation, aerospace, and industrial applications that rely most on forging for high-strength components.

The market is dominated by several major players, including Howmet Aerospace, Carlton Forge Works (PCC), Specialty Ring Products (SRP), Constellium, and Scot Forge, which are at the forefront. A broad portfolio, innovative product launches, and strong geographic presence expansion have supported the dominance of these companies in the U.S. market.

U.S. ALUMINUM FORGING MARKET TRENDS

Rapid Adoption of Automation, Digital Simulation & Smart Forging Technologies Leads to Market Trends

The U.S. aluminum forging industry is undergoing a major technological transformation as manufacturers shift toward automation, digital simulation, and smart forging systems to improve productivity, reduce waste, and increase consistency. This trend is driven by several U.S.-specific factors: rising labor shortages in skilled trades, the need for precise tolerance control for aerospace and electric vehicle components, and pressure to reduce operational costs due to raw material price volatility.

Modern forging plants are increasingly incorporating robotic billet handling, automated press loading, sensor-enabled furnaces, and closed-loop feedback systems that adjust force, temperature, and die-lubrication in real time. These technologies significantly reduce scrap, enhance repeatability, and ensure uniform mechanical properties—critical for aerospace and defense certifications such as AS9100 and NADCAP.

Digital simulation is becoming equally important. Advanced forging-simulation software allows engineers to test different die geometries, extrusion flows, and temperature profiles before production begins. This reduces trial-and-error, shortens development cycles, and helps manufacturers achieve near-net-shape components with minimal machining.

MARKET DYNAMICS

MARKET DRIVERS

Commercial and Defense Aircraft Production Expansion Boosting U.S. Aluminum Forging Demand

The expansion of aircraft manufacturing, driven by long-term commercial fleet growth and sustained defense modernization, provides a strong, predictable demand base for aluminum forgings. This combination ensures that the aerospace industry will continue to be one of the most influential growth drivers for the U.S. aluminum forging market.

According to the Federal Aviation Administration (FAA), long-term aerospace forecasts show that U.S. commercial aircraft fleets are expected to keep growing through 2045 as passenger demand rises and airlines continue large-scale fleet renewal programs, and according to the Congressional Research Service, citing the U.S. Department of Defense, military requirements for aluminum represent about 3% of total U.S. aluminum consumption, underlining the material’s continued importance in defense platforms.

Moreover, airlines are steadily updating older fleets, while military programs are investing in next-generation aircraft and advanced aviation systems. This creates a continuous need for forged aluminum components that offer dependable strength without excessive weight, making them ideal for landing gear parts, structural brackets, wing assemblies, and other high-load applications. As new aircraft platforms emphasize lighter, more efficient structures, forging companies remain closely integrated into long-term aerospace supply chains.

MARKET RESTRAINTS

Raw Material Price Instability is Limiting the Aluminum Forging Market Growth

Raw material price instability remains one of the major restraints for U.S. aluminum forging companies. Forgers heavily depend on aluminum billets and ingots, which are influenced by global supply, energy costs, and international trade conditions. When prices move sharply in a short period, forging businesses face higher costs without the ability to adjust contract terms immediately. Because many supply agreements are negotiated months ahead, unexpected increases in billet costs reduce profit margins and create financial pressure. This uncertainty makes forging companies more cautious about expanding production, purchasing new equipment, or taking on long-term commitments.

According to the U.S. Geological Survey (USGS), U.S. primary aluminum production has experienced notable year-to-year changes, with output measured in thousands of metric tons showing periods of significant growth as well as periods of marked decline across the historical data series. These shifts in domestic production contribute to an uneven supply environment, which in turn influences the prices paid by forging companies for the aluminum they need.

MARKET OPPORTUNITIES

Defense Procurement Upgrades Creating Strategic Expansion Opportunities for U.S. Aluminum Forgings

Defense procurement modernization is creating one of the strongest growth opportunities for aluminum forging companies in the United States. Military systems need parts that are lightweight, strong, and dependable under tough operating conditions. Forged aluminum meets these needs because it delivers consistent strength and supports reliable performance in aircraft, vehicles, naval equipment, missile systems, and other defense platforms.

• According to the U.S. Government Accountability Office (GAO), the F-35 program plans to procure 2,470 aircraft over its lifetime, showing a long-term commitment to building and sustaining a large fighter fleet, which in turn supports steady demand for high-quality aerospace parts.

Demand continues to grow as newer military systems look for materials that lower overall weight while still ensuring safety and durability. According to a recent aerospace-metals review, aluminum alloys currently account for about 60–80% of the structural weight in many commercial aircraft designs. This shows how important aluminum and the forged components made from it remain in current and future defense designs. These conditions create strong opportunities for U.S. forging companies.

MARKET CHALLENGES

Energy-Intensive Processes and Rising Utility Costs Pose a Market Challenge

Aluminum forging is inherently energy-intensive, requiring significant heat and power to process metal into high-strength components. Before forging begins, aluminum billets must be heated to elevated temperatures—often between 400°C and 500°C—using gas-fired or electric furnaces. Large forging presses, induction heaters, heat-treatment ovens, and quenching systems also consume a substantial amount of electricity. This makes energy one of the largest operating cost components for U.S. forging companies, especially those using older or less efficient equipment.

In recent years, U.S. industrial electricity and natural gas prices have fluctuated upward, driven by supply constraints, grid instability, and increased demand across the manufacturing sector. As a result, forging companies face higher production costs that directly impact profit margins, particularly for small and mid-sized facilities with limited ability to invest in modern, energy-efficient technologies.

Consequently, rising utility costs place pressure on U.S. aluminum forging manufacturers to upgrade their equipment, adopt more efficient heating systems, implement waste heat recovery, or integrate automation to optimize energy consumption. Until such investments are widespread, energy intensity will remain a structural challenge, affecting pricing, competitiveness, and long-term sustainability of U.S. forging operations.

Segmentation Analysis

By Forging Type

Closed Die Forging Segment to Capture Dominant Share Owing to Heavy Usage in the Automotive Industry

Based on forging type, the market is divided into closed die forging, open die forging, and ring rolled.

Closed-die forging is expected to hold the dominant share. This process is widely preferred for producing high-volume, precision aluminum components with excellent strength and dimensional accuracy. It is heavily used in the automotive industry, EV, aerospace, and defense applications, where near-net-shape parts reduce machining time and material waste. Growing demand for lightweight suspension arms, steering knuckles, aircraft fittings, and defense hardware further reinforces the segment’s leadership. Investments in automation and die-simulation technologies also strengthen closed-die forging’s competitive advantage.

By End-Use Industry

Aerospace and Defense Lead the Market Owing to the Rising Aircraft Production and Defense Modernization Programs

Based on end-use industry, the market is divided into aerospace and defense, automotive & transportation, industrial machinery, construction, and others.

The aerospace and defense segment is projected to hold the largest U.S. aluminum forging market share during the forecast period. This growth in the aluminum forging is driven by rising aircraft production, increasing defense modernization programs, and expanding demand for high-strength, lightweight structural components. Aluminum forgings are essential for critical aerospace parts such as landing gear components, wing and fuselage fittings, engine rings, and missile structures due to their superior fatigue resistance and reliability under extreme conditions.

The automotive & transportation segment is driven by strong demand for lightweight, high-strength components that improve fuel efficiency, safety, and performance. Forged aluminum parts

The industrial machinery segment is a prominent consumer of aluminum forged products and shows steady growth due to rising demand for durable, corrosion-resistant aluminum forgings across manufacturing, robotics, heavy equipment, compressors, pumps, and material-handling systems. Aluminum forged components offer strong mechanical properties, high reliability under cyclic loads, and the ability to operate in demanding industrial environments.

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COMPETITIVE LANDSCAPE

Key Industry Players

Players Strengthen Technological Capabilities and Supply Reliability to Sustain Market Leadership

As far as the competitive landscape is concerned, the U.S. aluminum forging market is moderately consolidated, characterized by the presence of a few large aerospace- and defense-certified forging houses alongside a wide base of mid-sized and specialized forging companies. Competition is driven by forging capability (closed-die, open-die, ring-rolled), capacity, alloy expertise, and industry certifications such as AS9100, NADCAP, and ISO standards.

The market has a significant number of regional and global key players operating worldwide. Some of these companies include Howmet Aerospace, Carlton Forge Works (PCC), Specialty Ring Products (SRP), Constellium, and Scot Forge, among many others.

LIST OF KEY U.S. ALUMINUM FORGING COMPANIES PROFILED

• Howmet Aerospace (U.S.)
• Carlton Forge Works (U.S.)
• Specialty Ring Products – SRP (U.S.)
• All Metals & Forge Group – AMFG (U.S.)
• Scot Forge (U.S.)
• Weber Metals (U.S.)
• Anchor Harvey (U.S.)
• Bourdon Forge (U.S.)
• Summit Machine, LLC (U.S.)
• DEECO Metals (U.S.)
• American Hand Forgings (U.S.)

KEY INDUSTRY DEVELOPMENTS

• April 2025: Anchor Harvey bought the PMG group of businesses, including D&N Machining in Greenwood, Arkansas, combining PMG’s precision machining expertise with its closed-die aluminum forging operations. April 2025: Anchor Harvey announced the official integration of the PMG family of businesses under the Anchor Harvey name, positioning the company as a one-stop provider of end-to-end metal component manufacturing solutions for OEMs and Tier 1 suppliers.
• December 2022: Weber Metals expanded its footprint by acquiring the Viking Metallurgical facility in Verdi, Nevada, marking a major strategic growth milestone. The 22-acre site, featuring over 100,000 sq ft of manufacturing space, brings a long-established expertise in high-temperature alloy rolled rings, strengthening Weber’s capabilities in advanced forging and metallurgical production.

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Report Scope & Segmentation