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.

The key promising market opportunities in the thermal spray market include: • Coatings Materials (Segmentation By Product Type) → Expected gain of $3343.83 Million • Cold Spray (Segmentation By Technology) → Expected gain of $1923.79 Million • Plasma Spray (Segmentation By Technology) → Expected gain of $1225.95 Million

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.

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.

How Will The Drivers Impact Growth In The Global Thermal Spray Market?

• Expansion Of Automotive Production (Medium) – The expansion of automotive production will become a key driver of growth in the thermal spray market by 2030. As global vehicle manufacturing—particularly electric vehicle (EV) output—continues to expand, demand for high-performance surface treatments will grow to enhance component durability, thermal resistance and wear protection. Government-backed investments in EV battery manufacturing and infrastructure. Autonomous vehicle technologies, highlighting the opportunity for thermal spray coatings to play a central role in emerging EV manufacturing paradigms. As automakers ramp up production and update processes to meet evolving regulatory standards and performance requirements, the integration of thermal spray technologies into automotive manufacturing workflows becomes more essential, thereby propelling market expansion during the forecast period. As a result, the expansion of automotive production is anticipated to contributing to a 1.8% annual growth in the market. • Growing Demand In Healthcare Equipment (Medium) – The growing demand in healthcare equipment will emerge as a major factor driving the expansion of the thermal spray market by 2030. The increasing need for advanced medical devices, driven by aging populations and rising chronic disease prevalence, is prompting substantial investments in durable and high-performance healthcare equipment. Healthcare providers are investing in sophisticated technologies such as diagnostic imaging systems, surgical instruments and patient monitoring tools, all of which benefit from enhanced surface engineering. Thermal spray coatings improve the wear resistance, corrosion protection, biocompatibility and sterilization durability of these devices, extending their performance and lifespan. As demand for medical equipment continues to climb, especially in hospital and home-care settings, thermal spray solutions become increasingly vital to meet stringent operational and regulatory requirements, thereby driving market growth during the forecast period. Consequently, the growing demand in healthcare equipment capabilities is projected to contributing to a 1.1% annual growth in the market. • Increase In Mining And Heavy Machinery Operations (Low) – The increase in mining and heavy machinery operations within digital manufacturing processes will serve as a key growth catalyst for the thermal spray market by 2030. As mining output and heavy equipment utilization expand globally, there is growing demand for surface protection technologies that extend equipment life and enhance performance under extreme conditions. Thermal spray coatings deliver highly durable wear and corrosion resistance, particularly valuable for parts like excavator buckets, crusher liners and conveyor components, supporting reduced downtime and maintenance. As mining and heavy machinery operations scale up, thermal spray becomes essential for protecting critical surfaces exposed to abrasion, erosion and harsh operational environments, thereby driving market growth during the forecast period. Therefore, this increase in mining and heavy machinery operations across digital manufacturing operations is projected to supporting to a 0.8% annual growth in the market. • Increasing Aerospace Industry Demand (Low) – The increasing aerospace industry demand will become a significant driver contributing to the growth of the thermal spray market by 2030. Government-supported aviation data shows sustained and broadening demand in air travel. This robust and regionally diverse increase in aerospace activity escalates the need for advanced surface engineering solutions. Thermal spray coatings, valued for providing wear resistance, thermal protection and corrosion durability, are increasingly vital for protecting critical components such as engine parts, structural airframes, satellite hardware and launch systems. As countries and operators expand aerospace manufacturing, modernize fleets and explore space markets, thermal spray technologies become integral, thereby propelling market growth during the forecast period. Consequently, the increasing aerospace industry demand is projected to contributing to a 0.5% annual growth in the market.

How Will The Restraints Impact Growth In The Global Thermal Spray Market?

• Availability Of Alternative Coating Technologies (Medium) – Availability Of Alternative Coating Technologies will restrict the growth of the Thermal Spray market during the forecast period. Thermal spray faces competition from alternative coating technologies including electroplating, PVD, and CVD. Alternative technologies offer different advantages for specific applications. Competition from substitutes can limit thermal spray market share and growth potential. • Skilled Workforce Shortage (Low) – Skilled Workforce Shortage will restrict the growth of the Thermal Spray market during the forecast period. Thermal spray operations require skilled technicians and engineers with expertise in coating processes and quality control. The shortage of qualified workforce affects production capacity and service quality. Labor gaps can lead to production delays and increased costs, limiting market growth. • Impact of Trade War and Tariff (Low) – Impact of Trade War and Tariff will restrict the growth of the Thermal Spray market during the forecast period. Thermal spray equipment and materials rely on imported components and specialty alloys subject to trade tariffs. Trade barriers can increase production costs and affect product availability. Trade tensions may also impact industrial production and coating service demand.

Key Players In The Global Thermal Spray Market

Major companies operating in the thermal spray market are Saint-Gobain Group, Linde plc, Sandvik AB, Aimtek Inc., OC Oerlikon Corporation AG, Curtiss-Wright Corporation, Kennametal Inc., Castolin Eutectic GmbH, Bodycote plc, Hoganas AB, Chromalloy Gas Turbine LLC, H.C. Starck Inc., FM Industries Inc., Fisher-Barton Group Inc., APS Materials Inc., Polymet Corporation, HAI Inc., Powder Alloy Corporation, ASB Industries Inc., Aisher APM LLC, C&M Technologies GmbH, Supersonic Spray Technologies, Metallizing Equipment Co. Pvt. Ltd

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.

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.