The U.S. aerospace testing market size was estimated at USD 1,585.8 million in 2024 and is projected to reach USD 2,167.4 million by 2033, growing at a compound annual growth rate (CAGR) of 3.6% from 2025 to 2033. The growth of the U.S. aerospace testing market is largely fueled by the increasing integration of remote inspection tools and digital twin technologies.

These advanced systems enable the creation of virtual replicas of aircraft and their subsystems, allowing for detailed assessments without direct physical interaction. The incorporation of high-resolution imaging and integrated data analytics enhances the accuracy of defect identification, which significantly reduces the reliance on large, on-site inspection teams and contributes to lowering operational costs for aerospace companies.

The application of extended reality (XR) is further transforming the testing process by facilitating virtual inspections and assessments across distributed fleets and remote locations. These technological developments are allowing aerospace companies to adopt more agile, responsive, and data-driven approaches to aircraft testing and maintenance.

For example, in April 2025, Gecko Robotics, Inc., an artificial intelligence and robotics firm based in the U.S., entered into a strategic partnership with L3Harris Technologies, Inc. Together, they developed an extended reality solution that generates high-resolution digital twins of aircraft, specifically for remote inspection and fault detection. This initiative not only increases the precision of testing activities but also plays a critical role in the modernization of military aircraft by supporting virtual maintenance processes and defect tracking.

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Key Market Trends & Insights

1) In 2024, the material testing segment emerged as the leading segment in the U.S. aerospace testing market, holding a 33.5% market share. This prominence is attributed to the escalating demand for high-performance materials that can endure extreme temperatures, pressures, and mechanical stress. These materials are essential for ensuring the structural reliability and safety of aircraft components, particularly as aerospace designs become more advanced and complex.

2) Aircraft structures also dominated the market in 2024, reflecting the vital need for comprehensive testing of airframes and related components. These structures are subject to repetitive stress cycles, high-speed operations, and environmental challenges that necessitate rigorous testing protocols to guarantee durability, performance, and compliance with aviation standards.

3) Commercial aviation accounted for the largest share of the U.S. aerospace testing market in 2024. The sector’s growth is driven by frequent aircraft upgrades, an increase in system complexity, and rising expectations for safety and fuel efficiency. Airlines are focusing on extensive validation processes for software, electronic systems, and mechanical structures to meet evolving regulatory and certification benchmarks.