Thermal Spray Market Size & Share Analysis - Growth Trends & Forecasts (2025 - 2030)

The Thermal Spray Market Report is Segmented by Product Type (Coatings, Materials, and Thermal Spray Equipment), Thermal Spray Coatings and Finishes (Combustion and Electric Energy), End-User Industry (Aerospace, Industrial Gas Turbines, Automotive, Electronics, Oil and Gas, Medical Devices, Energy and Power, Steel Making, Textile, and Printing and Paper), and Geography (Asia-Pacific, North America, Europe, South America, and Middle East and Africa). The Report Offers Market Sizes and Forecasts in Terms of Revenue (USD) for all the Above Segments.

Thermal Spray Market Size

Thermal Spray Market Summary

Compare market size and growth of Thermal Spray Market with other markets in Chemicals & Materials Industry

Thermal Spray Market Analysis

The Thermal Spray Market size is estimated at USD 13.03 billion in 2025, and is expected to reach USD 15.85 billion by 2030, at a CAGR of greater than 4% during the forecast period (2025-2030).

The thermal spray market was negatively affected by the COVID-19 pandemic. Initially, there was a slowdown in manufacturing activities due to lockdowns and supply chain disruptions, leading to a temporary decrease in demand for thermal spray coatings. However, as industries adopted new norms and increased their emphasis on hygiene and protection, there was a growing demand for thermal spray coatings in industries such as healthcare, automotive, and aerospace.

  • The increasing popularity of thermal spray ceramic coatings due to their usage in medical devices, the rising use of thermal spray coatings in the aerospace industry, and the replacement of hard chrome coatings are some factors driving the demand for the thermal spray market.
  • However, issues regarding process reliability and consistency and the emergence of hard trivalent chrome coatings in recent years are likely to hinder the market's growth.
  • The increasing demand for thermal spray from the oil and gas industry, recycling of thermal spray processing materials, and advancements in spraying technology (cold spray process) are expected to provide lucrative growth opportunities for the market in the coming years.
  • Asia-Pacific is expected to dominate the thermal spray market over the forecast period.

Asia-Pacific to Dominate the Market

  • Asia-Pacific is experiencing rapid industrialization, particularly in countries like China, India, Japan, and South Korea. The region's booming manufacturing sector, including the automotive, aerospace, electronics, and energy industries, is driving significant demand for thermal spray coatings to enhance component performance and durability.
  • Governments in Asia-Pacific are investing heavily in infrastructure projects, including transportation, energy, and construction. Thermal spray coatings protect critical infrastructure components from corrosion, wear, and erosion, thereby extending their lifespan and reducing maintenance costs.
  • China is one of the world's biggest aircraft manufacturers and a market for domestic air passengers, as stated by the Chinese Civil Aviation Administration. In addition, with more than 200 small aircraft component manufacturers, there has been rapid growth in the parts and assembly industry.
  • China is the largest electronics manufacturing base in the world. Electronic products such as smartphones, televisions, cables, mobile computers, gaming systems, and other consumer electronic equipment are being produced in China on an active basis. According to the CEIC, in December 2023, the export value of Chinese electronics products was USD 21.63 billion.
  • In 2023, South Korea received a total of USD 18.8 billion in investments from abroad, marking a 3.4% increase from the previous year. Specifically, the electronics industry saw the largest share of this investment, with USD 3 billion allocated, standing out as the top sub-industry.
  • China is one of the largest producers of steel globally. According to official figures, the nation's primary steel production reached 952.14 million tons during the initial 11 months of 2023, marking a 1.5% increase compared to the same period in the previous year.
  • The automotive industry in India plays a crucial role in technological advancements and macroeconomic expansion. According to the Society of Indian Automobile Manufacturers (SIAM), the number of vehicles sold from April 2023 to March 2024 reached 23,853,463, marking an increase of 12.5% from the 21,204,846 units sold in the same timeframe during FY 2023.
  • Due to the above-mentioned factors, the region is projected to dominate the market during the forecast period.
Thermal Spray Market - Growth Rate by Region

Thermal Spray Industry Overview

The thermal spray market is fragmented in nature. The major players (not in any particular order) include OC Oerlikon Management AG, Linde PLC (Praxair ST Technologies Inc.), Chromalloy Gas Turbine LLC, Bodycote, and Kennametal Inc.

Thermal Spray Market Leaders

  1. OC Oerlikon Management AG

  2. Kennametal Inc.

  3. Chromalloy Gas Turbine LLC

  4. Bodycote

  5. Linde PLC (Praxair ST Technologies Inc.)

  6. *Disclaimer: Major Players sorted in no particular order
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Thermal Spray Market News

  • June 2023: Castolin Eutectic launched XupersoniClad, a new thermal spraying technique containing supersonic spraying technology. This technology is developed from the high-velocity air-fuel (HVAF) process. It is also an effective solution for the new generation of high entropy alloys, such as HEA coatings.
  • June 2023: Oerlikon Metco IIoT transformed its thermal spray systems with a digital solution. This digital platform connects thermal spray systems within an Industry 4.0 platform.

Thermal Spray Market Report - Table of Contents

1. INTRODUCTION

  • 1.1 Study Assumptions
  • 1.2 Scope of the Study

2. RESEARCH METHODOLOGY

3. EXECUTIVE SUMMARY

4. MARKET DYNAMICS

  • 4.1 Drivers
    • 4.1.1 Increasing Usage of Thermal Spray Coatings in Medical Devices
    • 4.1.2 Rising Popularity of Thermal Spray Ceramic Coatings
    • 4.1.3 Replacement of Hard Chrome Coating
    • 4.1.4 Rising Use of Thermal Spray Coatings in the Aerospace Industry
  • 4.2 Restraints
    • 4.2.1 Emergence of Hard Trivalent Chrome Coatings
    • 4.2.2 Issues Regarding Process Reliability and Consistency
  • 4.3 Industry Value Chain Analysis
  • 4.4 Porter's Five Forces Analysis
    • 4.4.1 Bargaining Power of Suppliers
    • 4.4.2 Bargaining Power of Buyers
    • 4.4.3 Threat of New Entrants
    • 4.4.4 Threat of Substitute Products
    • 4.4.5 Degree of Competition

5. MARKET SEGMENTATION (Market Size in Value)

  • 5.1 Product Type
    • 5.1.1 Coatings Materials
    • 5.1.1.1 Powders
    • 5.1.1.1.1 Ceramics
    • 5.1.1.1.2 Metal
    • 5.1.1.1.3 Polymers and Other Powders
    • 5.1.1.2 Wires/Rods
    • 5.1.1.3 Other Coating Materials (Auxiliary Material)
    • 5.1.2 Thermal Spray Equipment
    • 5.1.2.1 Thermal Spray Coating System
    • 5.1.2.2 Dust Collection Equipment
    • 5.1.2.3 Spray Gun and Nozzle
    • 5.1.2.4 Feeder Equipment
    • 5.1.2.5 Spare Parts
    • 5.1.2.6 Noise-reducing Enclosures
    • 5.1.2.7 Other Thermal Spray Equipment
  • 5.2 Thermal Spray Coatings and Finishes
    • 5.2.1 Combustion
    • 5.2.2 Electric Energy
  • 5.3 End-user Industry
    • 5.3.1 Aerospace
    • 5.3.2 Industrial Gas Turbines
    • 5.3.3 Automotive
    • 5.3.4 Electronics
    • 5.3.5 Oil and Gas
    • 5.3.6 Medical Devices
    • 5.3.7 Energy and Power
    • 5.3.8 Steel Making
    • 5.3.9 Textile
    • 5.3.10 Printing and Paper
  • 5.4 Geography
    • 5.4.1 Asia-Pacific
    • 5.4.1.1 China
    • 5.4.1.2 India
    • 5.4.1.3 Japan
    • 5.4.1.4 South Korea
    • 5.4.1.5 Malaysia
    • 5.4.1.6 Thailand
    • 5.4.1.7 Indonesia
    • 5.4.1.8 Vietnam
    • 5.4.1.9 Rest of Asia-Pacific
    • 5.4.2 North America
    • 5.4.2.1 United States
    • 5.4.2.2 Canada
    • 5.4.2.3 Mexico
    • 5.4.3 Europe
    • 5.4.3.1 Germany
    • 5.4.3.2 United Kingdom
    • 5.4.3.3 France
    • 5.4.3.4 Italy
    • 5.4.3.5 Spain
    • 5.4.3.6 Turkey
    • 5.4.3.7 Russia
    • 5.4.3.8 NORDIC
    • 5.4.3.9 Rest of Europe
    • 5.4.4 South America
    • 5.4.4.1 Brazil
    • 5.4.4.2 Argentina
    • 5.4.4.3 Colombia
    • 5.4.4.4 Rest of South America
    • 5.4.5 Middle East and Africa
    • 5.4.5.1 South Africa
    • 5.4.5.2 Saudi Arabia
    • 5.4.5.3 Nigeria
    • 5.4.5.4 Egypt
    • 5.4.5.5 Qatar
    • 5.4.5.6 United Arab Emirates
    • 5.4.5.7 Rest of Middle East and Africa

6. COMPETITIVE LANDSCAPE

  • 6.1 Mergers and Acquisitions, Joint Ventures, Collaborations, and Agreements
  • 6.2 Market Share (%)**/Ranking Analysis
  • 6.3 Strategies Adopted by Leading Players
  • 6.4 Company Profiles
    • 6.4.1 Thermal Spray Material Companies
    • 6.4.1.1 Aimtek Inc.
    • 6.4.1.2 AISher APM LLC
    • 6.4.1.3 AMETEK Inc.
    • 6.4.1.4 C&M Technologies GmbH
    • 6.4.1.5 CASTOLIN EUTECTIC
    • 6.4.1.6 CenterLine (Windsor) Limited (Supersonic Spray Technologies Division)
    • 6.4.1.7 CRS Holdings LLC
    • 6.4.1.8 Fisher Barton
    • 6.4.1.9 Global Tungsten & Powders
    • 6.4.1.10 H.C. Starck Inc.
    • 6.4.1.11 HAI Inc
    • 6.4.1.12 Hoganas AB
    • 6.4.1.13 Hunter Chemical LLC
    • 6.4.1.14 Kennametal Inc.
    • 6.4.1.15 Linde PLC (Praxair ST Technologies Inc.)
    • 6.4.1.16 LSN Diffusion Limited
    • 6.4.1.17 Metallisation Limited
    • 6.4.1.18 Metallizing Equipment Co. Pvt. Ltd
    • 6.4.1.19 OC Oerlikon Management AG
    • 6.4.1.20 Polymet
    • 6.4.1.21 Powder Alloy Corporation
    • 6.4.1.22 Saint-Gobain
    • 6.4.1.23 Sandvik AB
    • 6.4.1.24 Thermion
    • 6.4.2 Thermal Spray Coatings Companies
    • 6.4.2.1 APS Materials Inc.
    • 6.4.2.2 Bodycote
    • 6.4.2.3 Chromalloy Gas Turbine LLC
    • 6.4.2.4 Curtiss-Wright Corporation (FW Gartner)
    • 6.4.2.5 Fisher Barton
    • 6.4.2.6 FM Industries
    • 6.4.2.7 Hannecard Roller Coatings, Inc (ASB Industries Inc.)
    • 6.4.2.8 Lincotek Trento SpA
    • 6.4.2.9 Linde PLC (Praxair ST Technologies Inc.)
    • 6.4.2.10 OC Oerlikon Management AG
    • 6.4.2.11 Thermion
    • 6.4.2.12 TOCALO Co. Ltd
    • 6.4.3 Thermal Spray Equipment Companies
    • 6.4.3.1 Air Products and Chemicals Inc.
    • 6.4.3.2 Arzell Inc.
    • 6.4.3.3 ASB Industries Inc. (Hannecard Roller Coatings Inc.)
    • 6.4.3.4 Bay State Surface Technologies Inc. (Aimtek Inc.)
    • 6.4.3.5 Camfil Air Pollution Control (APC)
    • 6.4.3.6 CASTOLIN EUTECTIC
    • 6.4.3.7 Centerline (Windsor) Ltd (SUPERSONIC SPRAY TECHNOLOGIES)
    • 6.4.3.8 Donaldson Company Inc.
    • 6.4.3.9 Flame Spray Technologies BV
    • 6.4.3.10 GTV Verschleibschutz GmbH
    • 6.4.3.11 HAI Inc.
    • 6.4.3.12 Imperial Systems Inc.
    • 6.4.3.13 Kennametal Inc.
    • 6.4.3.14 Lincotek Equipment SpA
    • 6.4.3.15 Linde PLC (Praxair ST Technologies Inc.)
    • 6.4.3.16 Metallisation Limited
    • 6.4.3.17 Metallizing Equipment Co. Pvt. Ltd
    • 6.4.3.18 OC Oerlikon Management AG
    • 6.4.3.19 Plasma Powders
    • 6.4.3.20 Powder Feed Dynamics Inc.
    • 6.4.3.21 Progressive Surface
    • 6.4.3.22 Saint-Gobain
    • 6.4.3.23 Thermion
  • *List Not Exhaustive

7. MARKET OPPORTUNITIES AND FUTURE TRENDS

  • 7.1 Advancements in Spraying Technology (Cold Spray Process)
  • 7.2 Recycling of Thermal Spray Processing Materials
  • 7.3 Increasing Demand From The Oil and Gas Industry
**Subject to Availability
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Thermal Spray Industry Segmentation

Thermal spraying is an industrial coating process where a consumable is applied as a spray of finely divided semi-molten or molten droplets to produce coatings and then deposit them onto a surface. It is a technology that improves or restores the surface of a solid material. Thermal spraying aids in applying coatings to various materials and components to resist wear, corrosion, cavitation, abrasion, or heat. 

The thermal spray market is segmented by product type, thermal spray coatings and finishes, end-user industry, and geography. By product type, the market is segmented into coatings, materials, and thermal spray equipment. By thermal spray coatings and finishes, the market is segmented into combustion and electric energy. By end-user industry, the market is segmented into aerospace, industrial gas turbines, automotive, electronics, oil and gas, medical devices, energy and power, steel making, textile, and printing and paper. The report also covers the market sizes and forecasts for the thermal spray market in 27 countries across major regions. For each segment, the market size and forecast are provided based on revenue (USD).

Product Type Coatings Materials Powders Ceramics
Metal
Polymers and Other Powders
Wires/Rods
Other Coating Materials (Auxiliary Material)
Thermal Spray Equipment Thermal Spray Coating System
Dust Collection Equipment
Spray Gun and Nozzle
Feeder Equipment
Spare Parts
Noise-reducing Enclosures
Other Thermal Spray Equipment
Thermal Spray Coatings and Finishes Combustion
Electric Energy
End-user Industry Aerospace
Industrial Gas Turbines
Automotive
Electronics
Oil and Gas
Medical Devices
Energy and Power
Steel Making
Textile
Printing and Paper
Geography Asia-Pacific China
India
Japan
South Korea
Malaysia
Thailand
Indonesia
Vietnam
Rest of Asia-Pacific
North America United States
Canada
Mexico
Europe Germany
United Kingdom
France
Italy
Spain
Turkey
Russia
NORDIC
Rest of Europe
South America Brazil
Argentina
Colombia
Rest of South America
Middle East and Africa South Africa
Saudi Arabia
Nigeria
Egypt
Qatar
United Arab Emirates
Rest of Middle East and Africa
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Thermal Spray Market Research FAQs

How big is the Thermal Spray Market?

The Thermal Spray Market size is expected to reach USD 13.03 billion in 2025 and grow at a CAGR of greater than 4% to reach USD 15.85 billion by 2030.

What is the current Thermal Spray Market size?

In 2025, the Thermal Spray Market size is expected to reach USD 13.03 billion.

Who are the key players in Thermal Spray Market?

OC Oerlikon Management AG, Kennametal Inc., Chromalloy Gas Turbine LLC, Bodycote and Linde PLC (Praxair ST Technologies Inc.) are the major companies operating in the Thermal Spray Market.

Which is the fastest growing region in Thermal Spray Market?

Asia-Pacific is estimated to grow at the highest CAGR over the forecast period (2025-2030).

Which region has the biggest share in Thermal Spray Market?

In 2025, the Asia-Pacific accounts for the largest market share in Thermal Spray Market.

What years does this Thermal Spray Market cover, and what was the market size in 2024?

In 2024, the Thermal Spray Market size was estimated at USD 12.51 billion. The report covers the Thermal Spray Market historical market size for years: 2019, 2020, 2021, 2022, 2023 and 2024. The report also forecasts the Thermal Spray Market size for years: 2025, 2026, 2027, 2028, 2029 and 2030.

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