Aerospace Manufacturing in 2025: Navigating Key Challenges and Innovations

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Aerospace Industry Shifts Focus to Defense Amidst Emerging Technologies

LONDON – A new survey conducted jointly by the Royal Aeronautical Society (RAeS) and digital manufacturing specialists Protolabs reveals a meaningful shift within the aerospace industry,with defense production now dominating strategic priorities. The 2025 findings, released today, highlight a move away from previous concerns surrounding supply chain disruptions and sustainability challenges, indicating a growing demand to meet the needs of both domestic and international defense sectors.

The survey, which gathered insights from 165 aerospace professionals globally, found that 44.4% identified as engineers, followed by a diverse ‘Other’ category at 17.28%. Participants included representatives from major aerospace firms like Airbus, BAE Systems, Boeing, GE Aerospace, and Rolls-Royce, alongside numerous educational institutions, signifying a collaborative approach to modern manufacturing.

Defense Dominates Strategic Vision

Initial survey questions revealed that, while sustainability remains a key concern, ‘scaling up defense’ has emerged as the primary focus for the aerospace industry. A remarkable 63.19% of respondents cited this as their top priority, surpassing sustainability at 61.96% and recruiting skilled personnel at 47.24%.This shift reflects the ongoing geopolitical instability, especially in Ukraine and the Middle East, which is driving increased demand for aerospace products and services across defense applications.Over three-quarters (79.50%) of companies reported adjusting their business models to cater to defense sector requirements.

Despite a continuing 36.81% acknowledgement of supply chain challenges, the downward trend suggests these issues are gradually receding. Looking ahead,respondents identified ‘new technologies’ as the most influential factor in the industry’s future-61.96% anticipate a significant role for advancements. Close behind were sustainability at 55.83%, recruiting skilled personnel and scaling up defense, each with 50.31% support. the decline in emphasis on post-COVID civil production, previously highlighted at 47.9%,further reinforces the industry’s strategic realignment.

Speed, Quality, and Cost: A Shifting Hierarchy

Crucially, the survey revealed an increased emphasis on speed of delivery, with 54.66% of respondents identifying it as a critical design and manufacturing factor – a significant rise from 36% in 2023. Quality remained paramount, holding a strong 84.47% ranking.However,cost considerations have moved down the priority list,with only 47.20% considering it a key factor this year, compared to 57.21% in 2024 and 30% in 2023. Automation is rapidly changing the landscape,with 1.88% of companies now operating entirely on automated processes,a significant increase from 0.28% in 2024 and 0.46% in 2023, while the proportion using no automation has decreased to 15.63% from 26.32% in 2024.

3D Printing and AI Lead technological Advancement

The most commonly used prototyping and manufacturing technologies continue to evolve. 3D printing led the pack with 69.14% adoption, followed by CNC machining at 54.32% and robotic manufacturing at 50%. Interestingly,the use of Artificial Intelligence (AI) is also gaining traction,with 54.19% leveraging it for administrative tasks and 49.03% using it as a virtual assistant. While relatively few (32.26%) employ AI in design work, 15.48% utilize it for certification, and 14.19% for the manufacturing process itself.

Year	3D Printing (%)	CNC Machining (%)	Robotic Manufacturing (%)
2023	51.51%	53.85%	44.88%
2024	74.09%	51.41%	57.72%
2025	69.14%	54.32%	50.00%

Key Challenges Remain

Despite the industry’s shift, significant challenges persist. ‘Project costs’ remains the top concern, followed by ‘lack of expertise’ and ‘skills shortages.’ This collaborative effort between the RAeS and Protolabs offers a vital insight into the ongoing evolution of the aerospace manufacturing sector as it adapts to evolving technological demands and geopolitical realities.

This survey underscores a broader trend: the aerospace industry’s increasing responsiveness to global events and strategic shifts. As geopolitical tensions rise and defense budgets expand, companies focused on innovation and agile manufacturing solutions are best positioned for long-term success. The continued rise of technologies like 3D printing and AI, coupled with a focus on speed and quality, will undoubtedly shape the future of aerospace production.

Frequently Asked Questions

• What is the primary focus of the aerospace industry according to the 2025 survey?

  Scaling up defense production was identified as the number one priority, reflecting increased geopolitical pressures.

• How has the emphasis on sustainability changed since 2023?

  While still a consideration,sustainability has moved down the list,with ‘scaling up defense’ now taking the lead.

• What technological advancements are most frequently cited by aerospace professionals?

  3D printing is currently the most widely used prototyping/manufacturing technology.

• Which factor is most important when designing and manufacturing parts for the industry?

  Speed of delivery is now prioritized over quality and cost.

• What percentage of companies are using automation in their manufacturing processes?

  Approximately 1.88% of companies utilize all automated processes.

• What are the primary challenges facing the aerospace industry in adopting digital manufacturing techniques?

  Project costs, lack of expertise, and skills shortages remain the most significant obstacles.

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"articleBody": "A new survey conducted jointly by the royal Aeronautical Society (RAeS) and digital manufacturing specialists Protolabs reveals a significant shift within the aerospace industry, with defense production now dominating strategic priorities. The 2025 findings, released today, highlight a move away from previous concerns surrounding supply chain disruptions and sustainability challenges, indicating a growing demand to meet the needs of both domestic and international defense sectors.nnThe survey, which gathered insights from 165 aerospace professionals globally, found that 44.4% identified as engineers, followed by a diverse 'Other' category at 17.28%. Participants included representatives from major aerospace firms like Airbus, BAE Systems, Boeing, GE Aerospace, and Rolls-Royce, alongside numerous educational institutions, signifying a collaborative approach to modern manufacturing.nnPrioritising defensennThe first key question of the annual survey, which allowed respondents to tick all that applied, was: 'What is the main focus for the aerospace industry currently?' In 2023 the number one focus was the need to recruit more skilled personnel (52.9%), followed by sustainability (51.6%) and supply chain shortages (50.7%).nnIn 2024, sustainability rose to the number one spot with 65.33% listing it as their major concern. This was followed by recruiting more skilled personnel (56.49%) and supply chain shortages (31.14%). This year, sustainability continued to lead the way (63.19% of respondents), with recruiting more skilled personnel remaining in second place (47.24%) but 'scaling up defence' jumped into third place (46.63%). With conflict continuing to rage in Ukraine and the Middle East and an increasingly uncertain geopolitical horizon, the shift in emphasis towards defence and away from sustainability is perhaps to be expected. More than three quarters (79.50%) of the survey's respondents saeid their companies were adjusting their business models to meet demand from the defense sector.nnMeanwhile, even though 36.81% still considered supply chain shortages to be an issue, this downward trend would appear to suggest that the worst of the crisis has passed.nnLooking to the future, those surveyed were asked what areas they saw aerospace focusing on over the next three years. Of the categories provided, 'New technologies' was the most common response, with 61.96% including it in their future gazing. This was closely followed by 'Sustainability' (55.83%) with 'recruiting more skilled personnel' and 'Scaling up defence' tying in third place, each with 50.31%. 'Ramping up civil production post-Covid' trailed with a score of just 33.13% - a drop from 47.9% in 2023, that once again suggests the supply chain issues in the civil aerospace sector are now considered far less of a concern.Respondents were given the option to answer 'Other' and specify their answers, which 6.13% did. The suggestions ranged from battling competition from China and India to cabin safety, but there were trends towards profitability, cost-efficiency and economic 'survival'.nnSpeed of deliverynnOnce again, the shift toward defence is an obvious change compared to previous survey results, and answers to the question 'What are the key factors considered when designing and manufacturing parts for the industry?' also suggested that the need to expedite design and delivery is becoming ever more critically important. In 2025, 54.66% of those surveyed said 'Speed' was a key factor, an increase from 36% in 2023. Understandably, 'Quality' remained the most popular answer (84.47% in 2025 compared to 94.22% in 2024 and 64% in 2023) but 'Cost' fell to the third most important priority this year. While 47.20% of respondents listed it as a priority this year,57.21% did so in 2024 and 30% did so in 2023.nnIn 2023, having 'Experts on hand' was the third most popular answer to the question, but in 2024 this had fallen to fourth place and this year it lies in fifth, with automation jumping from sixth in 2024 to third in 2025. Asked about what percentage of their business' manufacturing services are now automated, 1.88% said that all of their processes now used automation (an increase from 0.28% in 2024 and 0.46% in 2023). conversely, the number stating that none of their business processes were automated fell to 15.63% in 2025 from 26.32% in 2024, albeit this was still higher than the 2023 level of 11.12%.nnPrinting the futurennIn response to the question 'What are the key prototyping/manufacturing technologies currently being used in the aerospace sector?',respondents could once again tick all options that applied and the 2025 results indicated that 3D printing was the most commonly used method (69.14%) followed by CNC machining (54.32%) and robotic manufacturing (50%). This compares to 2024 when 3D printing was 74.09%, robotic manufacturing was 57.72% and CNC machining was 51.41% and 2023 when CNC machining led the way at 53.85%, followed by 3D printing (51.51%) and robotic manufacturing (44.88%). This year, 11.11% of respondents listed 'Other' as key manufacturing techniques with many listing 'AI' as an option.nnWhen quizzed specifically about their use of AI within the workplace, 54.19% of respondents said that they used it to assist with admin duties and 49.03% said they used it as a virtual assistant. Some 43.23% used AI transcription services but just 32.26% used AI for design work, 15.48% used it for certification and 14.19% for manufacturing.nnFigures for in-house manufacturing remained reasonably consistent with previous years, with 16.05% saying they did produce in-house, 29.63% producing less than 25% of their material in-house and 28.40% producing between 25-50% in house. Just 17.9% produced 50-75% in-house with 8.02% producing more than 75% of their own material. These figures suggest a slight increase compared to previous years' responses, with just 10.83% in 2023 and 23.15% in 2024 producing no material in-house.nnPrinting the futurennIn response to the question 'What are the key prototyping/manufacturing technologies currently being used in the aerospace sector?', respondents could once again tick all options that applied and the 2025 results indicated that 3D printing was the most commonly used method (69.14%) followed by CNC machining (54.32%) and robotic manufacturing (50%). This compares to 2024 when 3D printing was 74.09%, robotic manufacturing was 57.72% and CNC machining was 51.41% and 2023 when CNC machining led the way at 53.85%, followed by 3D printing (51.51%) and robotic manufacturing (44.88%). This year, 11.11% of respondents listed 'Other' as key manufacturing techniques with many listing 'AI' as an option.nnWhen quizzed specifically about their use of AI within the workplace, 54.19% of respondents said that they used it to assist with admin duties and 49.03% said they used it as a virtual assistant. Some 43.23% used AI transcription services but just 32.26% used AI for design work, 15.48% used it for certification and 14.19% for manufacturing.nnFigures for in-house manufacturing remained reasonably consistent with previous years, with 16.05% saying they did produce in-house, 29.63% producing less than 25% of their material in-house and 28.40% producing between 25-50% in house. Just 17.9% produced 50-75% in-house with 8.02% producing more than 75% of their own material. These figures suggest a slight increase compared to previous years' responses, with just 10.83% in 2023 and 23.15% in 2024 producing no material in-house.nn

nnThe greatest challengennWhen quizzed on 'What do you think are the greatest challenges facing the aerospace industry during adoption of digital manufacturing techniques?' respondents were once again given six options and asked to rank them. 'Project costs' was ranked top of the challenges for the second consecutive year with 'Lack of expertise' once again ranking second and 'Skills shortages' in third place. nnOnce again, this collaboration between the RAeS and Protolabs provides a unique and valuable snapshot of the aerospace manufacturing industry in 2025 and how it continues to evolve to incorporate new technologies to meet the chnn

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How can aerospace manufacturers effectively mitigate risks associated with concentrated supply chains for critical components like titanium and semiconductors?

The Evolving Landscape of Aerospace Production

Aerospace manufacturing in 2025 is defined by a confluence of factors: surging demand,supply chain vulnerabilities exposed by recent global events,and a relentless push for sustainability. This isn't simply about building more planes; it's about building them differently. Key areas driving change include advanced materials, digital twins, automation, and a renewed focus on workforce growth. The industry is undergoing a meaningful change, impacting everything from commercial aviation to space exploration.

Key Challenges Facing Aerospace Manufacturers

Several significant hurdles are impacting aerospace production today. Addressing these is crucial for maintaining competitiveness and meeting future demand.

* Supply Chain Resilience: The fragility of global supply chains was starkly revealed in recent years. Dependence on single sources for critical components, like titanium and specialized semiconductors, creates significant risk. diversification and regionalization of supply chains are now paramount.

* Skilled Labor Shortage: A looming skills gap threatens to stifle innovation and production capacity. Experienced machinists, composite technicians, and engineers are in high demand, but supply is limited.Retraining programs and attracting younger generations to STEM fields are vital.

* Rising Material Costs: Raw material prices, particularly for aluminum, titanium, and carbon fiber, have fluctuated considerably.This impacts profitability and necessitates exploring alternative materials and efficient resource management.

* Sustainability Pressures: The aviation industry faces increasing pressure to reduce its carbon footprint. This drives demand for lighter materials, more fuel-efficient designs, and enduring aviation fuels (SAF).

* Geopolitical instability: Global political tensions and trade disputes introduce uncertainty and potential disruptions to international collaborations and supply routes.

Innovations Shaping the Future of Aerospace

Despite the challenges, aerospace manufacturing is brimming with innovation. These advancements are poised to revolutionize how aircraft and spacecraft are designed, built, and maintained.

Advanced Materials: Beyond Aluminum and Titanium

The quest for lighter,stronger,and more durable materials is relentless.

* Carbon Fiber Reinforced Polymers (CFRP): Already widely used, CFRP continues to evolve with improved manufacturing processes and cost reductions.

* Ceramic Matrix Composites (CMCs): Offering exceptional heat resistance and strength-to-weight ratios, CMCs are crucial for engine components and hypersonic vehicles.

* aluminum-Lithium Alloys: Providing weight savings and improved strength compared to traditional aluminum alloys.

* Self-Healing Materials: Emerging research focuses on materials capable of repairing minor damage autonomously, extending component lifespan and reducing maintenance.

Digital Transformation: The Power of Data

Digital technologies are fundamentally changing aerospace manufacturing processes.

* Digital twins: Virtual replicas of physical assets (aircraft,engines,components) enable predictive maintenance,performance optimization,and accelerated design cycles.

* Additive Manufacturing (3D Printing): increasingly used for prototyping, tooling, and even production of complex parts. Benefits include reduced material waste, faster lead times, and design freedom. Examples include GE Additive's work on fuel nozzles.

* Artificial Intelligence (AI) and Machine Learning (ML): AI/ML algorithms are being deployed for quality control, process optimization, and predictive maintenance.

* Internet of Things (IoT): Sensors embedded in manufacturing equipment and aircraft provide real-time data for monitoring performance and identifying potential issues.

Automation and Robotics: Increasing Efficiency

Automation is crucial for addressing the labor shortage and improving production efficiency.

* Automated Fiber Placement (AFP) and Automated Tape laying (ATL): Robotic systems precisely lay down composite materials, ensuring consistent quality and reducing labor costs.

* Robotic Drilling and Fastening: Automated systems improve speed and accuracy in assembly processes.

* Cobots (Collaborative Robots): Working alongside human operators, cobots assist with tasks requiring precision and strength.

* Automated Inspection systems: Utilizing computer vision and machine learning to detect defects and ensure quality control.

Sustainable Manufacturing Practices

Reducing the environmental impact of aerospace manufacturing is a top priority.

* Closed-Loop Manufacturing: Recycling and reusing materials to minimize waste.

* Energy Efficiency: Implementing energy-saving technologies and optimizing manufacturing processes.

* Sustainable Aviation Fuels (SAF): Developing and adopting SAF to reduce carbon emissions from flight.

* Lean Manufacturing Principles: Eliminating waste and improving efficiency throughout the production process.

Case Study: Airbus's Digital transformation

Airbus has been a leader in adopting digital technologies. Their implementation of digital twins for aircraft maintenance has resulted in significant cost savings and improved aircraft availability. By analyzing data from sensors and flight records, Airbus can predict potential maintenance needs and schedule repairs proactively, minimizing downtime. This demonstrates the tangible benefits of embracing digital transformation in aerospace.

Practical Tips for aerospace manufacturers in 2025

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