Thermal Spray Coatings Market - Global Industry Size, Share, Trends, Opportunity, and Forecast, Segmented By Material (Ceramic, Metal & Alloys, Others), By End User (Healthcare, Aerospace, Automotive, Agriculture, Electronics, Others), By Region and Competition, 2020-2030F

Market Overview

The Global Thermal Spray Coatings Market, valued at USD 10.69 Billion in 2024, is projected to experience a CAGR of 4.59% to reach USD 14.00 Billion by 2030. Thermal spray coatings represent a surface engineering technique involving the deposition of melted or semi-molten metallic or ceramic materials onto a substrate to enhance its functional properties or facilitate remanufacture. Main drivers supporting market growth include the escalating demand for advanced protective solutions across diverse industrial sectors, such as aerospace, automotive, and healthcare, seeking improved wear, corrosion, and thermal resistance. Additionally, the increasing focus on extending component lifespan and improving operational efficiency, alongside the replacement of traditional surface treatments like hard chrome plating due to regulatory pressures and superior performance, propels market expansion. For instance, according to the International Air Transport Association, in August 2023, domestic commercial aerospace passenger traffic rose by 9.2% relative to pre-pandemic levels, indicating a strong rebound in a key end-user industry driving coating demand.

A significant challenge impeding market expansion is the substantial initial capital investment required for thermal spray equipment and system setup. This high entry barrier can limit market penetration, particularly for small and medium-sized enterprises. Furthermore, the technical complexities associated with application processes and the necessity for specialized personnel pose ongoing operational hurdles within the industry.

Key Market Drivers

The global thermal spray coatings market is significantly influenced by the escalating demand for advanced wear and corrosion protection solutions across diverse industrial sectors. Components in industries such as aerospace, automotive, and energy are continuously subjected to harsh operating conditions, including extreme temperatures, abrasive environments, and corrosive agents, which necessitate robust surface enhancements to extend lifespan and ensure reliable performance. The inherent ability of thermal spray coatings to impart superior hardness, erosion resistance, and corrosion barriers makes them essential for safeguarding critical machinery and structural parts. For example, according to a SciOpen research article titled "Influence of tribology on global energy consumption, costs and emissions", published in 2024, the total global costs of friction and wear amount to 250 billion Euros annually, underscoring the substantial economic imperative driving the adoption of protective coating technologies. This pervasive need for enhanced durability and operational integrity directly fuels market expansion for thermal spray applications.

Concurrently, strict environmental regulations are a pivotal factor stimulating the shift towards thermal spray coatings as alternatives to traditional surface treatments like hard chrome plating. Regulatory bodies globally are increasingly restricting the use of hazardous substances, particularly hexavalent chromium compounds, due to their environmental and health risks. This regulatory pressure mandates industries to adopt safer and more sustainable coating solutions, positioning thermal spray processes as a compliant and high-performance replacement. For instance, according to Foresight, in August 2024, the article 'Upcoming EU Decisions on Hexavalent Chromium: Key Dates and Implications' highlighted that several existing authorizations for chromium trioxide and other hexavalent chromium substances were set to expire on September 21, 2024, compelling industries to transition. This regulatory-driven substitution creates a substantial market pull for thermal spray technologies. Overall, the thermal spray coatings market, exemplified by major industry participants, continues to demonstrate robust activity, as according to Oerlikon's 2023 Full Year Results, published in February 2024, its Surface Solutions division reported sales of CHF 1,521 million in 2023.

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Key Market Challenges

The substantial initial capital investment required for thermal spray equipment and system setup presents a significant impediment to the growth of the Global Thermal Spray Coatings Market. This high entry barrier particularly restricts market penetration for small and medium-sized enterprises (SMEs), which often lack the extensive financial resources necessary to acquire specialized machinery. Such investments can involve outlays ranging from hundreds of thousands to several million dollars, depending on the system's complexity, automation level, and required capacity.

The consequence of this financial hurdle is a reduced rate of adoption of advanced thermal spray technologies among potential new market participants and existing smaller firms seeking expansion or modernization. This dynamic limits overall market growth by concentrating advanced surface engineering capabilities predominantly within larger corporations, thereby hindering broader industrial application and innovation. According to the National Association of Manufacturers' Q1 2024 survey, nearly 40% of manufacturing respondents reported pulling back on investment activities due to increased costs related to capital expenditures, directly illustrating how financial pressures curtail crucial market development. This underscores the direct impact of capital cost sensitivity on the market's expansion potential.

Key Market Trends

The integration of automation and robotics into thermal spray coating applications represents a transformative trend, enhancing process precision, consistency, and operational efficiency. This shift mitigates human error, optimizes material usage, and accelerates production cycles, which is critical for meeting stringent quality demands in industries such as aerospace and automotive. According to the International Federation of Robotics (IFR), in September 2024, worldwide industrial robot installations reached 541,302 units in 2023, signifying a continuous drive towards automation in manufacturing processes generally. This broader adoption reflects the increasing confidence in robotic solutions for complex manufacturing tasks, directly influencing thermal spray operations. Furthermore, Oerlikon and MTU Aero Engines, in July 2024, initiated the establishment of a smart thermal spray factory, leveraging digitalization to achieve unprecedented productivity and efficiency in aerospace component production. This highlights the industry's commitment to fully automated and digitally integrated coating lines.

The expansion of hybrid additive manufacturing and thermal spray repair techniques is profoundly influencing the market by extending the lifecycle of high-value components and enabling complex part refurbishment. This trend combines the design flexibility and material customization of additive manufacturing with the protective and restorative capabilities of thermal spray. According to ASTM International, in July 2024, its Additive Manufacturing Center of Excellence (AM CoE) launched a Certification Committee to develop audit criteria for qualifying AM facilities, reflecting the increasing industrial adoption and standardization of additive manufacturing for critical applications. The synergy allows for the repair of components that would otherwise be scrapped, thereby reducing waste and operational costs. For example, Siemens Energy, as reported in September 2025, has integrated additive manufacturing into its turbine maintenance strategy, utilizing metal 3D printing to accelerate repairs and modernize older components, achieving repair time reductions of up to 90%. This demonstrates the direct economic and operational benefits derived from these combined technologies in demanding industrial environments.

Segmental Insights

The Ceramic segment is a key growth driver within the Global Thermal Spray Coatings Market, experiencing rapid expansion due to its exceptional material properties and broadening industrial applications. This accelerated growth is primarily attributed to ceramic coatings' superior thermal barrier capabilities, which are crucial for protecting components in high-temperature environments such as aerospace engine parts and industrial gas turbines. Additionally, their outstanding resistance to wear and corrosion significantly enhances the longevity and reliability of machinery in harsh operational settings, including automotive and manufacturing sectors. The increasing adoption of ceramic coatings in the biomedical industry, owing to their inherent biocompatibility for medical implants, further contributes to this segment's robust market trajectory.

Regional Insights

North America holds a dominant position in the global thermal spray coatings market, driven by its robust industrial base and extensive adoption across several key sectors. The region's leadership is primarily attributable to the strong presence of well-established aerospace and defense industries, which heavily rely on these coatings for enhanced component performance and durability in extreme operating conditions. Furthermore, significant demand from the automotive sector for improved fuel efficiency and wear resistance in critical parts, alongside continuous exploration activities in the oil and gas industry requiring corrosion and erosion protection, further solidify North America's market dominance. The increasing application in the healthcare sector for biocompatible medical devices also contributes to this leading position.

Recent Developments

• In July 2025, Oerlikon Metco introduced "Surface Two™," an advanced thermal spray platform designed for larger components and high-performance production. This new system is built for smart manufacturing, integrating precision engineering, modular flexibility, and digital capabilities to ensure consistent coating quality and operational efficiency across various industries. Surface Two™ features increased capacity, rapid deployment, and enhanced automation, including Industrial Internet of Things (IIoT) capabilities. The platform aims to facilitate the handling of larger components, accelerate changeovers, and adapt to evolving production demands within the global thermal spray coatings market.

• In May 2025, Saint-Gobain Coating Solutions presented a breakthrough technology in thermal spraying known as Cord Plasma Spray (CPS) at the International Thermal Spray Conference and Exposition (ITSC). This new robust process has the potential to produce advanced coatings for industrial gas turbine (IGT) and aerospace applications. The company developed various microstructures by combining specialized YSZ cords, containing fine powders, with an axial injection torch. This innovation addresses the challenge of achieving a robust and industrial-scale plasma spray process, particularly when utilizing suspension plasma spray (SPS) or co-spraying dissimilar materials.

• In January 2025, Höganäs and Blykalla announced a strategic partnership to develop specialized materials for Blykalla's small modular reactor (SMR) technology. Höganäs will utilize its expertise in advanced metal powder technologies to develop and produce corrosion-resistant alloys for cladding critical SEALER components, specifically tubular products. This collaboration focuses on industrializing, qualifying, and commercializing these materials to ensure performance and durability in liquid lead environments. The initiative underscores the importance of a resilient supply chain for advanced reactor technologies and aims to drive innovation in clean energy sectors, directly impacting the specialized thermal spray coatings market.

• In March 2024, Hardide Coatings introduced the first product in its new range of Hardide Enhanced Components. This initial offering was a JP-5000 4-inch copper nozzle specifically designed for High-Velocity Oxy-Fuel (HVOF) thermal spray coating applications. The tungsten/tungsten carbide-based Hardide® chemical vapor deposition (CVD) coating significantly extends the operational life of these nozzles by 5 to 40 times when spraying carbide or metallic powders. This advancement aims to enhance productivity and reduce spraying costs within the thermal spray coatings market by minimizing pickup inside the nozzle and improving coating quality.

Key Market Players

• Praxair Surface Technologies, Inc.
• Arkema SA
• Höganäs AB
• H.C. Starck Inc.
• Wall Colmonoy Corporation
• Powder Alloy Corporation
• Saint-Gobain S.A.
• Carpenter Technology Corporation
• Durum Verschleiss-Schutz GmbH
• Montreal Carbide Co. Ltd.

Report Scope:

In this report, the Global Thermal Spray Coatings Market has been segmented into the following categories, in addition to the industry trends which have also been detailed below:

• Thermal Spray Coatings Market, By Material:

o   Ceramic

o   Metal & Alloys

o   Others

• Thermal Spray Coatings Market, By End User:

o   Healthcare

o   Aerospace

o   Automotive

o   Agriculture

o   Electronics

o   Others

• Thermal Spray Coatings Market, By Region:

o   North America

§  United States

§  Canada

§  Mexico

o   Europe

§  France

§  United Kingdom

§  Italy

§  Germany

§  Spain

o   Asia Pacific

§  China

§  India

§  Japan

§  Australia

§  South Korea

o   South America

§  Brazil

§  Argentina

§  Colombia

o   Middle East & Africa

§  South Africa

§  Saudi Arabia

§  UAE

Competitive Landscape

Company Profiles: Detailed analysis of the major companies presents in the Global Thermal Spray Coatings Market.

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Global Thermal Spray Coatings Market report with the given market data, TechSci Research offers customizations according to a company's specific needs. The following customization options are available for the report:

Company Information

• Detailed analysis and profiling of additional market players (up to five).

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