AI cuts aerospace material development cycles by over 50%: report

AI-led simulation and materials design are helping manufacturers cut discovery timelines.

Aerospace manufacturers are now turning to AI to keep up with the accelerating competitive and technological changes and the necessary materials gathering required to thrive, according to a report by Kearney.

The global aerospace market is projected to grow by $42.9b by 2029, but traditional material discovery has struggled to keep up with the demand.

Conventional development of a new aircraft may take 15 to 20 years from concept to production certification. AI speeds this up by helping companies discover, test, validate, and optimise material, Kearney said.

AI’s reach and impact spans all stakeholders across the industry, starting with aerospace original equipment manufacturers (OEMs).

OEMs can use AI-engineered materials to speed up R&D, create lighter and stronger designs, and build more resilient supply chains.

In turn, governments and regulators such as public agencies and defense bodies must modernise certification and data infrastructure to safely integrate AI-driven materials, the report suggests.

For investors, understanding where AI unlocks cost, sustainability, and performance gains is becoming central to investment strategy.

Suppliers and research institutions, including material producers, research labs, and technology firms, must align with OEMs through shared data ecosystems and co-development models to convert digital insights into manufacturable materials.

Sustainability in the industry will depend on how effectively these stakeholders work together using the technology available to them.