U.S. Metal Powder Market Size, Share, Trends, & Industry Analysis Report By Production Method (Chemical, Mechanical, and Physical), By Type, By Application, By End Use– Market Forecast, 2025–2034

The U.S. metal powder market size is expected to reach USD 2.59 billion by 2034, according to a new study by Polaris Market Research. The report “U.S. Metal Powder Market Share, Size, Trends, Industry Analysis Report: By Production Method (Chemical, Mechanical, and Physical), By Type, By Application, By End Use; Market Forecast, 2025–2034” gives a detailed insight into current market dynamics and provides analysis on future market growth.

Metal powder consists of fine particles of metallic elements such as iron, aluminum, copper, or titanium, produced through methods like atomization, reduction, or electrolysis. It is widely used in powder metallurgy to manufacture precision components for automotive, aerospace, and medical industries via processes like sintering and 3D printing. Metal powders also serve in additive manufacturing (AM), enabling complex, lightweight structures with minimal waste. Additionally, they are utilized in coatings, welding, and chemical applications.

The U.S. metal powder industry is a key contributor to advanced manufacturing and defense technologies. American producers supply high-quality powders such as titanium, nickel, and aluminum alloys used in aerospace, medical implants, and additive manufacturing. The industry benefits from strong research support, stringent quality standards, and integration with defense and space programs such as those of NASA and the Department of Defense.

U.S. Metal Powder Market Report Highlights

In terms of production method, the chemical segment accounted for 60.55% of the revenue share in 2024 due to its ability to produce powders with high purity, uniform particle size distribution, and superior quality, which industries such as automotive, aerospace, and healthcare highly demand.

Based on type, the ferrous segment held 88.65% of the revenue share in 2024 due to its widespread use in automotive, industrial machinery, and construction applications.

The non-ferrous segment is expected to grow at a CAGR of 7.62% from 2025 to 2034, owing to the rising adoption of lightweight and high-performance materials in aerospace, defense, and electric vehicle production.

In terms of application, the press & sinter segment accounted for 74.00% from 2025 to 2034, owing to its role in producing high-volume components for automotive, industrial, and consumer goods.

Based on end use, the aerospace & defense segment is estimated to grow at a CAGR of 8.95% from 2025 to 2034, owing to the increasing use of additive manufacturing to produce lightweight, high-strength components with precise geometries.

A few key market players include Alcoa Corporation, AMETEK Inc., ATI Inc., Carpenter Technology Corporation, GKN Powder Metallurgy, Höganäs AB, Kymera International, Linde PLC, Metal Powder Works, and Sandvik AB.

Polaris Market Research has segmented the market report on the basis of production method, type, application, and end use:

By Production Method Outlook (Revenue, USD Billion, 2020–2034)

Chemical

Mechanical

Physical

By Type Outlook (Revenue, USD Billion, 2020–2034)

Ferrous

Non-ferrous

By Application Outlook (Revenue, USD Billion, 2020–2034)

Additive Manufacturing

Press & Sinter

Metal Injection Molding

Others

By End Use Outlook (Revenue, USD Billion, 2020–2034)

Automotive

Industrial

Aerospace & Defense

Construction

Healthcare

Others Show more