Friction Stir Welding Market Top Players, Segments & Regional Trends By 2033

Friction stir welding is a solid-state joining process that uses a rotating tool to generate frictional heat, softening materials without melting them. This technique produces high-strength, defect-free joints with minimal distortion. The global friction stir welding market is driven by the growing demand for lightweight and energy-efficient vehicles, the expansion of railway and shipbuilding infrastructure, and the increasing use of dissimilar materials to enhance structural performance.

Market Dynamics Rising need for cost-efficient, high-quality welding processes drives the global market

The global friction stir welding (FSW) market is propelled by the increasing demand for welding processes that combine high quality with cost efficiency. Industries are adopting FSW to achieve stronger, more reliable joints while reducing production costs and minimizing material waste.

• For instance, in June 2025, KUKA secured a follow-up order from a major U.S. automaker for 12 additional FSW production cells for electric vehicle battery case manufacturing. The expansion came after initial systems demonstrated defect-free welds, lower inspection costs, and enhanced efficiency.

These trends underscore FSW's growing role as a solution that delivers both economic and technical benefits, meeting industry demands for precision, sustainability, and performance.

Ongoing technological innovations are creating significant growth opportunities in the global friction stir welding market, as industries increasingly require faster, smarter, and more cost-effective welding solutions. New systems are being developed to improve weld precision, enhance energy efficiency, and integrate seamlessly with automated production lines.

• For example, in April 2025, Bodor introduced its ECO Series handheld laser welding machine, offering full-rated power and faster welding speeds while cutting labor costs by up to 50%. The system is also automation-ready, demonstrating how innovation is reshaping welding processes.

These advancements highlight the market's move toward high-performance, flexible welding technologies tailored to the evolving demands of automotive, aerospace, and energy sectors.

Regional Analysis

North America holds a dominant position due to advanced manufacturing infrastructure, strong aerospace and automotive industries, and significant R&D investments. The region benefits from early adoption of automated FSW systems and integration with Industry 4.0 technologies. High demand for lightweight vehicle components, EV battery trays, and aerospace-grade structures is driving market growth. Moreover, leading companies and research institutions are continuously developing innovative FSW solutions to improve productivity, joint quality, and energy efficiency, reinforcing North America's leadership in the FSW landscape.

Key Highlights

• The global friction stir welding market size was valued at USD 289.53 million in 2024 and is estimated to grow from USD 306.29 million in 2025 to reach USD 493.18 million by 2033, growing at a CAGR of 6.22% during the forecast period (2025–2033).
• By Equipment Type, the market is segmented into Fixed FSW Equipment (Stationary Machines), Portable FSW Equipment, Robotic FSW Systems, and others. The fixed FSW equipment segment dominates the global market.
• By Material Type, the market is segmented into Aluminum Alloys, Magnesium Alloys, Copper & Copper Alloys, Steel & Stainless Steel, Titanium Alloys, and others. The steel & stainless-steel segment dominates the global market.
• By Automation Level, the market is segmented into Manual / Semi-Automated FSW Machines, Fully Automated & CNC-Integrated Systems, and Integration with Industry 4.0 & Digital Twin Technology. The fully automated & CNC-integrated systems segment dominates the global market.
• By End Use Industry, the market is segmented into Automotive & Transportation, Aerospace & Defense, Shipbuilding, Railway, Construction & Infrastructure, and others. The automotive & transportation segment dominates the global market.
• North America is the highest shareholder in the global market.