Report

Composite Repair Market Analysis

The composite repair market stood at USD 15.34 billion in 2025 and is forecast to rise to USD 21.31 billion by 2030, delivering a 6.79% CAGR. Growth continues as asset owners pivot from costly replacements to efficient composite repairs that restore structural performance while curbing downtime. Structural repairs remain the anchor segment, supported by deep certification expertise, yet cosmetic repairs are advancing fastest as preventive maintenance gains favor across wind, marine, and transportation assets. Aerospace keeps the largest end-user share, while offshore wind drives incremental demand for in-situ blade work that cannot be moved onshore. Digital twin integration, automation, and standards such as ASME PCC-2 and ISO 24817 ensure quality, contain risk, and underpin expanding adoption across critical infrastructure.

Global Composite Repair Market Trends and Insights



Surging Investment in Ageing-Asset Life-Extension Programs

Operators extend pipelines, aircraft, and industrial plants instead of replacing them, and composite wraps help execute this strategy without shutting down assets. T.D. Williamson's purchase of Petro-Line in December 2024 brought PETROSLEEVE technology into its portfolio, enabling live pipeline reinforcement that meets North American integrity mandates . HJ3 restored a highway bridge column at half the replacement cost using carbon-fiber wraps, illustrating the economic benefit for public infrastructure. Offshore wind blade replacements cost about USD 200,000 each, yet composite repairs average USD 30,000, making life-extension compelling for owners.

Cost Advantages of On-Site Composite Repair Versus Metallic Part Replacement

Composite overwraps avoid hot-work permits, lower insurance premiums, and reduce man-hours versus weld-based metallic repairs. ASME PCC-2 guidance notes that composites can eliminate 70-80% of hot work, materially improving safety and productivity. The Royal Australian Navy reports 15-year durability on carbon-fiber overlays for frigate decks, providing a long proof record at sea. Sika logged CHF 11.76 billion in 2024 sales, partly driven by infrastructure repair resins that extend asset life with minimal downtime. These economics contribute +1.5 points to growth as budget-constrained owners choose composite solutions.

Emergence of Self-Healing Composite Laminates

Academic breakthroughs show composites that autonomously close micro-cracks, potentially lowering future repair demand. Waseda University released a siloxane film in April 2025 that heals after heating while retaining 1.50 GPa hardness. Texas A&M's Diels-Alder polymer combines ballistic resistance and self-repair functions, attracting defense interest. These concepts remain pre-commercial yet illustrate a future scenario that could reduce aftermarket volumes, trimming 0.7 points from the CAGR beyond 2029.

Other drivers and restraints analyzed in the detailed report include:

Increasing Use of Composites in the Aerospace and Defense Industry / Offshore Wind Blade Length Growth Demanding In-Situ Repair Capability / Scarcity of Certified Composite Repair Technicians /

For complete list of drivers and restraints, kindly check the Table Of Contents.

Segment Analysis

Structural repairs accounted for 44.56% of the composite repair market share in 2024 as owners prioritize restoring load-bearing capacity on aircraft, pipelines, and wind blades. The segment benefits from rigorous certification protocols that favor established providers, especially in aerospace where composite primary structures demand precise scarf geometry and controlled cure profiles. Operators adopt these repairs to extend safe service intervals and defer capital-intensive replacements, reinforcing segment leadership inside the composite repair market.

Cosmetic repairs are rising at a 7.66% CAGR to 2030, reflecting the shift to early-stage interventions that address surface erosion before it propagates. Wind turbine leading-edge treatments, such as Belzona coatings, exemplify how cosmetic activities cut aerodynamic losses and avoid larger structural campaigns. As predictive maintenance tools flag minor surface defects earlier, the composite repair market size attached to the cosmetic category will expand, encouraging service providers to develop fast-cure, field-friendly systems that align with tight outage windows.

The hand lay-up method held 38.55% of composite repair market share in 2024 because of its portability and minimal equipment requirement. Field teams often rely on hand lay-up when weather, geometry, or access challenges rule out automated approaches. CompositePatch's five-minute emergency kits illustrate the advantage in maritime incidents where rapid hull sealing prevents costly downtime.

Autoclave repairs exhibit an 8.03% forecast CAGR as operators insist on aerospace-grade quality for highly loaded components. Airlines route engine cowls and flight-control surfaces to autoclave shops to regain qualification levels equal to original builds. As fleets grow, the composite repair market size for autoclave services will climb because airlines favor centralized, repeatable quality over field expediency. Vacuum infusion and automated fiber placement continue to advance, spurred by equipment manufacturers such as Ingersoll Machine Tools that supply robotics to MRO centers.

The Composite Repair Market Report Segments the Industry by Product Type (Structural, Semi-Structural, and More), Repair Process (Hand Lay-Up, Vacuum Infusion, and More), Material Type (Carbon-Fibre Reinforced Polymer (CFRP), Aramid-Fibre Composites, and More), End-User Industry (Automotive, Wind Energy, and More), and Geography (Asia-Pacific, North America, and More). The Market Forecasts are Provided in Terms of Value (USD).

Geography Analysis

Asia-Pacific commands the largest composite repair market because of its immense manufacturing base, expanding offshore wind pipelines, and ambitious infrastructure renewal plans. China's wind OEMs deploy fleets of 15-MW class turbines, fueling demand for in-situ blade servicing technologies. India and Southeast Asia register high single-digit growth as road, rail, and port projects integrate composite strengthening to meet accelerated timelines.

North America follows, underpinned by an aging energy network and a robust commercial aviation fleet. Pipeline operators apply ASME-qualified carbon overwraps to mitigate corrosion while maintaining throughput, and MRO houses in the United States invest in autoclave capacity for wide-body nacelles. The region also pilots digital twin deployments for predictive blade repairs on Great Plains wind farms.

Europe remains technology-centric with state incentives that drive R&D. Germany's aerospace cluster works on thermoplastic scarf-less patching, and Denmark pioneers blade robotics. Lufthansa Technik's EUR 1.2 billion expansion underscores local commitment to composite MRO leadership. Composite repair market size growth in Europe stabilizes at mid-single digits as the installed base matures but demands more sophisticated upkeep. Latin America, the Middle East, and Africa collectively form a smaller yet rapidly advancing bloc, adopting proven techniques from mature regions while cultivating domestic technician pipelines.

List of Companies Covered in this Report:

3M / Belzona International Ltd. / Boeing / ClockSpring / Composite Technology Inc. / Crawford Composites LLC / DIAB Group / Gurit Holding AG / HAECO Group / Henkel AG & Co. KGaA / Hexcel Corporation / Lufthansa Technik AG / Milliken Infrastructure Solutions / ResinTech Inc. / Sika AG / TD Williamson Inc. / TEAM, Inc. / Toray Advanced Composites / WR Composites /

Additional Benefits:

The market estimate (ME) sheet in Excel format /
3 months of analyst support /