Thermal Spray Market Report 2026

Thermal Spray Market Overview

• Thermal Spray market size has reached to $12.11 billion in 2025 • Expected to grow to $15.94 billion in 2030 at a compound annual growth rate (CAGR) of 5.6% • Growth Driver: Growth of Energy And Power Industries Fuels Thermal Spray Market • Market Trend: Advancements In Thermal Spray Technology Enhanced Coating Quality And Efficiency • North America was the largest region in 2025 and Asia-Pacific is the fastest growing region.

What Is Covered Under Thermal Spray Market?

Thermal spray is a coating process that involves spraying molten or semi-molten materials onto a surface to form a protective or decorative coating. It improves surface properties, such as wear resistance, corrosion protection, and thermal insulation. Thermal spray aims to extend the lifespan of components, enhance their performance, and reduce maintenance costs. The main product types of thermal spray are coatings, materials, and thermal spray. Coating refers to a layer of material applied to a surface for protection, decoration, or functional purposes. The technology such as cold spray, flame spray, plasma, and spray utilized by end users such as aerospace, industrial gas turbine, automotive, electronics, oil and gas, medical devices, and energy and power.

What Is The Thermal Spray Market Growth Forecast?

The thermal spray market size is expected to see strong growth in the next few years. It will grow to $15.94 billion in 2030 at a compound annual growth rate (CAGR) of 5.6%. The growth in the forecast period can be attributed to increasing demand for lightweight durable components, growth in electric vehicle manufacturing, expansion of power generation infrastructure, advancements in spray materials, rising automation in coating processes. Major trends in the forecast period include rising adoption of thermal spray for wear resistant coatings, growing use in aerospace and automotive components, increasing demand for corrosion protection solutions, expansion of thermal barrier coatings in energy systems, higher integration of automated thermal spray equipment.

Global Thermal Spray Market Segmentation

1) By Product Type: Coatings, Materials, Thermal Spray Equipment 2) By Technology: Cold Spray, Flame Spray, Plasma 3) By End-User Industry: Aerospace, Industrial Gas Turbines, Automotive, Electronics, Oil And Gas, Medical Devices, Energy And Power Subsegments: 1) By Coatings: Ceramic Coatings, Metal Coatings, Composite Coatings, Carbide Coatings, Zinc And Aluminum Coatings (For Corrosion Protection), Thermal Barrier Coatings, Wear-Resistant Coatings, Anti-Friction Coatings 2) By Materials: Powder Materials (Metal, Ceramic, Alloy Powders), Wire Materials (Metal Wires For Spray Coating), Rod Materials (For Specific Thermal Spraying Techniques), Bonding Materials (Primers And Adhesives), Gas And Liquid Fuels (Used For Thermal Spray Processes) 3) By Thermal Spray Equipment: Spray Guns (Plasma Spray Guns, Hvof Guns), Plasma Spray Equipment, Flame Spray Equipment, High-Velocity Oxygen Fuel (Hvof) Equipment, Arc Spray Systems, Wire Feeders, Powder Feeders, Control And Monitoring Systems For Thermal Spraying

What Is The Driver Of The Thermal Spray Market?

The growing energy and power industries are expected to propel the growth of the thermal spray market going forward. Energy and power industries encompass sectors involved in generating, transmitting, distributing, and utilizing energy resources to meet various societal needs. The energy and power industries are growing due to increasing global electricity demand, advancements in renewable energy technologies, and efforts to transition to cleaner and more sustainable energy sources. The energy and power sector utilizes thermal spray coatings to enhance turbine efficiency, prolong equipment lifespan, and mitigate corrosion in various components. For instance, in July 2025, according to the Office for National Statistics (ONS), a UK-based national statistical institute, in 2023, the electricity, gas, steam, and air conditioning supply industry within the UK low carbon and renewable energy economy (LCREE) recorded a turnover of £20.2 ($23.46) billion. Therefore, the growing energy and power industries will drive the thermal spray industry.

What Is The Driver Of The Thermal Spray Market?

The growing energy and power industries are expected to propel the growth of the thermal spray market going forward. Energy and power industries encompass sectors involved in generating, transmitting, distributing, and utilizing energy resources to meet various societal needs. The energy and power industries are growing due to increasing global electricity demand, advancements in renewable energy technologies, and efforts to transition to cleaner and more sustainable energy sources. The energy and power sector utilizes thermal spray coatings to enhance turbine efficiency, prolong equipment lifespan, and mitigate corrosion in various components. For instance, in July 2025, according to the Office for National Statistics (ONS), a UK-based national statistical institute, in 2023, the electricity, gas, steam, and air conditioning supply industry within the UK low carbon and renewable energy economy (LCREE) recorded a turnover of £20.2 ($23.46) billion. Therefore, the growing energy and power industries will drive the thermal spray industry.

Global Thermal Spray Market Trends and Insights

Major companies in the thermal spray market are focused on developing advanced solutions, such as supersonic spraying technology, to improve coating quality, enhance productivity, and address emerging industry challenges. Supersonic spraying technology in thermal spraying refers to a process where particles are accelerated to velocities exceeding the speed of sound, resulting in high coating quality and increased efficiency. For instance, in June 2023, Castolin Eutectic, a Germany-based company that provides surface protection solutions, launched the XupersoniClad, a new thermal spraying service that leverages supersonic spraying technology. This service is designed to provide an effective solution for new-generation high-entropy alloy (HEA) coatings, which combine five or more elements to outperform traditional materials. It is a warm spray process that operates at lower temperatures and higher velocities than traditional high-velocity oxy-fuel (HVOF) processes, making it more efficient and effective.

What Are Latest Mergers And Acquisitions In The Thermal Spray Market?

In December 2023, Kymera International, a US-based industrial coating manufacturing company, acquired Metallisation Ltd for an undisclosed amount. This strategic acquisition aims to bolster Kymera's surface technologies division by expanding its thermal spray solutions, positioning both companies as global leaders in thermal spray applications, particularly in the UK and European regions, and leveraging their combined strengths for mutual benefit and growth. Metallisation Limited is a UK-based supportive coating manufacturing company that manufactures thermal and metal spray equipment.

Regional Insights

North America was the largest region in the thermal spray market in 2025. Asia-Pacific is expected to be the fastest-growing region in the forecast period. The regions covered in this market report are Asia-Pacific, South East Asia, Western Europe, Eastern Europe, North America, South America, Middle East, Africa The countries covered in this market report are Australia, Brazil, China, France, Germany, India, Indonesia, Japan, Taiwan, Russia, South Korea, UK, USA, Canada, Italy, Spain

What Defines the Thermal Spray Market?

The thermal spray market consists of sales of spray guns, feeders, consumables, and auxiliary materials. Values in this market are ‘factory gate’ values, that is the value of goods sold by the manufacturers or creators of the goods, whether to other entities (including downstream manufacturers, wholesalers, distributors and retailers) or directly to end customers. The value of goods in this market includes related services sold by the creators of the goods.

How is Market Value Defined and Measured?

The market value is defined as the revenues that enterprises gain from the sale of goods and/or services within the specified market and geography through sales, grants, or donations in terms of the currency (in USD unless otherwise specified). The revenues for a specified geography are consumption values that are revenues generated by organizations in the specified geography within the market, irrespective of where they are produced. It does not include revenues from resales along the supply chain, either further along the supply chain or as part of other products.

What Key Data and Analysis Are Included in the Thermal Spray Market Report 2026?

The thermal spray market research report is one of a series of new reports from The Business Research Company that provides market statistics, including industry global market size, regional shares, competitors with the market share, detailed market segments, market trends and opportunities, and any further data you may need to thrive in the thermal spray industry. The market research report delivers a complete perspective of everything you need, with an in-depth analysis of the current and future state of the industry.