Thermal Spray Coatings Market Size, Share and Growth Forecast for 2025 - 2032

Thermal Spray Coatings Market Size and Share Analysis

The global thermal spray coatings market is likely to be valued at US$ 12.1 Bn in 2025, and is expected to reach US$ 18.3 Bn by 2032 with a significant growth rate of 6.1% from 2025 to 2032.

The demand for thermal spray coatings is primarily driven by the rising production and maintenance activities across key industries such as automotive, aerospace, power, and oil & gas. These coatings provide enhanced protection against wear and erosion, corrosion, friction, and both electrical and thermal damage; making them ideal for safeguarding new and existing components operating in harsh industrial environments. With the growing need for high-performance and durable products, particularly in the automotive and aerospace sectors, the adoption of thermal spray coatings is expected to gain further momentum in the coming years.

The thermal spray coatings market involves the application of coatings to surfaces using a heat source to enhance properties such as wear resistance, corrosion resistance, and thermal protection. This technology is widely utilized across various industries, including aerospace, automotive, healthcare, energy, and manufacturing.

Key Industry Highlights:

• Ceramic coatings dominate the global thermal spray coatings market due to their superior thermal barrier and corrosion resistance properties, making them highly preferred in aerospace and gas turbine applications.
• Plasma spray and High Velocity Oxy-Fuel (HVOF) processes are gaining widespread adoption, owing to their ability to produce dense, high-performance coatings, particularly for engine components and industrial machinery.
• The aerospace industry remains the largest end-use market, spurred by increasing aircraft production, maintenance, and the need for lightweight yet durable materials in jet engines, landing gear, and structural components.
• Medical applications of thermal spray coatings are rapidly expanding, especially in orthopedic and dental devices, where bio-compatible coatings such as hydroxyapatite enhance osseointegration and implant longevity.
• North America, particularly th    e U.S., holds a significant share of the thermal spray coatings market due to its well-established aerospace and defense industries that extensively use these coatings for engine components, landing gear, and turbine blades.
• Asia Pacific is witnessing robust growth in demand for thermal spray coatings, driven by expanding automotive manufacturing, industrial machinery, and power generation sectors in countries like China, India, and Japan.

Global Market Attribute	Key Insights
Thermal Spray Coatings Market Size (2025E)	US$ 12.1 Bn
Projected Market Value (2032F)	US$ 18.3 Bn
Forecast Growth Rate (CAGR 2025 to 2032)	6.1%
Historical Growth Rate (CAGR 2019 to 2024)	5.4%

Market Dynamics

Growth Driver - Environmental Sustainability Concerns Impel Need for thermal spray coatings

Environmental sustainability concerns are a significant growth driver for the thermal spray coatings market. As awareness of the environmental impact of traditional meat production increases, including greenhouse gas emissions, deforestation, and water usage, consumers are seeking eco-friendlier alternatives.

Thermal spray coatings offer a solution by requiring fewer natural resources and generating lower emissions compared to animal farming. This shift towards sustainable consumption is particularly appealing to environmentally conscious consumers who prioritize reducing their carbon footprint and preserving natural ecosystems.

The demand for thermal spray coating products is thus on the rise, driven by their perceived benefits in promoting environmental sustainability and ecological balance.

Promotion of Plant-Based Diets Through Systems Social Media and Influencer Marketing

Social media and influencer marketing play a crucial role in promoting plant-based diets, driving growth in the thermal spray coatings market. Platforms like Instagram, YouTube, and TikTok are filled with influencers and content creators who share recipes, health benefits, and environmental impacts of plant-based eating.

Such influencers reach diverse and broad audiences, creating trends and fostering a community around plant-based lifestyles. Their endorsements and engaging content make plant-based diets more appealing and accessible, encouraging followers to try and adopt these diets.

Additionally, social media campaigns by Thermal Spray Coatings companies amplify their reach, providing information and enticing visuals that resonate with younger, health-conscious consumers, thus boosting market demand and growth.

Restraint - Environmental Regulations and high equipment costs challenges adoption

Stringent environmental regulations are a significant factor impeding the growth of the thermal spray coatings market. Regulations restrict the use of certain coating materials due to their environmental impact, such as high levels of volatile organic compounds (VOCs) or hazardous chemicals.

Compliance with these regulations often requires expensive modifications to existing formulations or the development of new, eco-friendly alternatives. These constraints can lead to increased production costs and slower innovation, potentially limiting market expansion and making it challenging for companies to meet both regulatory requirements, and customer demands.

High equipment costs are a major barrier to the widespread adoption and implementation of thermal spray coatings. The technology requires specialized, expensive equipment for applying and controlling the coatings, which can be a significant financial burden for smaller companies or new market entrants.

The initial capital investment needed for purchasing and maintaining such equipment can limit access and slow down adoption, especially in developing regions.

In addition, high costs can lead to longer return on investment periods, making it less attractive for businesses to invest in thermal spray technology. This financial constraint impedes market growth by restricting the expansion and accessibility of advanced coating solutions.

Opportunity - Advancements in Automation for Precision Thermal Spray Applications

Advancements in automation present significant future opportunities for thermal spray coatings companies. Automation technologies, such as robotic arms and computer-controlled systems, enhance the precision and consistency of thermal spray applications.

Such innovations reduce human error, increase production efficiency, and allow for complex coating geometries that were previously challenging to achieve. As automation improves, companies can offer more reliable and high-quality coatings across various industries.

Additionally, automation can lower operational costs and improve scalability, making advanced coatings more accessible and attractive to a broader range of industries and applications.

Expansion in Renewable Energy Sector for Protective Coatings Applications

The expansion in the renewable energy sector presents promising future opportunities for thermal spray coatings companies. As renewable energy technologies, such as wind turbines, solar panels, and hydroelectric systems, become more prevalent, the demand for protective coatings to enhance durability and performance grows.

Thermal spray coatings can provide essential protection against environmental factors like corrosion, wear, and extreme temperatures, which are critical for maintaining the efficiency and longevity of renewable energy infrastructure.

With the sector’s rapid growth and increasing investment, there is a rising need for advanced coatings that can withstand harsh conditions and extend equipment life.

This market trend offers thermal spray coatings companies the chance to develop and supply specialized solutions tailored to the renewable energy market, driving innovation and market expansion.

Category-wise Analysis

Aerospace Demand Drives MRO Growth and Product Need

Category	Projected CAGR Through 2032
End-Use Industry - Aerospace	4.7%
Process - Plasma Spray	3.8%

In 2025, aerospace held a dominant revenue share of over 37.3% in the application segment of the thermal spray coatings market. Because aircraft parts are susceptible to deterioration from hot corrosion, fretting, particle erosion, and metal-to-metal wear, this is explained by the high demand for aerospace products.

Many aircraft manufacturers are looking for new aftermarket services income prospects because of the pandemic's impact on customer demand and pricing pressure. The demand for products in aerospace applications may rise because of the anticipated growth in maintenance, repair, and overhaul (MRO) operations.

Plasma Spray Technology Excels in Diverse, High-Performance Coatings

In 2025, the market was dominated by the plasma spray technology segment, which held a revenue share of approximately 32.0%. The reason for this is that the technique minimizes substrate deformation on both big and tiny components while having the benefit of spraying metallic and ceramic materials onto diverse surfaces with great binding strength.

offers the substrate surface electrical conductivity, wear resistance, clearance control, and heat and oxidation resistance. Printing rolls, gas turbines, industrial diesel engine piston rings, and oil and gas gear are all coated using a plasma thermal spray method.

Furthermore, because this technique can generate a dense and porous surface layer, surface roughness, and microstructure of the coatings based on the demand, it is widely used in the coating of orthopedic and dental implants.

Region-wise Analysis

North America Leads with Strong Sector Demand and Funding

Region	CAGR through 2032
North America	5.5 %

North America dominated the market with a 33.6% revenue share in 2025, fueled by strong demand in aerospace, oil & gas, automotive, medical, and power generation sectors. Government initiatives in the US, and Canada, which fund innovative coating projects, further bolster the expansion of the thermal spray coatings market in the region.

The Canadian government announced in February 2022 that it would allocate US$ 18.92 Mn (CAD 24 million) through the New Frontiers in Research Fund to a project aimed at creating novel molecular coatings that could reduce maintenance costs in a variety of industries, including consumer electronics, healthcare, automotive, aerospace, and infrastructure.

Competitive Landscape

The competitive landscape of the global thermal spray coatings market is characterized by a mix of established players and emerging companies. Key players, such as Oerlikon Metco, Praxair Surface Technologies, and Chromalloy, dominate with advanced technologies and extensive portfolios.

These companies focus on innovation, quality, and expanding applications to maintain market leadership. Emerging companies are leveraging new technologies and specialized coatings to capture niche segments.

Strategic partnerships, acquisitions, and R&D investments are common strategies to enhance capabilities and market reach. The market is also witnessing increased competition due to growing demand in aerospace, automotive, and industrial sectors.

Recent Industry Developments

• In Jun 2023, Applied Materials, Inc. and IIT Ropar worked together to do research and development for the thermal spray coating sector, which serves the semiconductor industry.
• In Jun 2023, digitalization and the introduction of Metco IIoT, the first business 4.0 platform specifically designed for the thermal spray business, are two major developments in thermal spray equipment that OC Oerlikon Management AG announced.
• In May 2023, Thermal Spray Solutions, Inc. (TSS), a top supplier of thermal spray coatings for wear and corrosion protection to the US Navy and shipbuilding industry, was acquired by Kymera International. This will strengthen the company's plan to grow the special coatings business area.

Companies Covered in Thermal Spray Coatings Market

• Praxair Surface Technologies
• Bodycote
• Oerlikon Metco
• Curtiss-Wright Surface Technologies
• Sulzer
• Kennametal Stellite
• Metallisation Ltd
• Linde
• Saint-Gobain
• TWI Ltd
• Höganäs AB
• H.C. Starck
• Plasma-Tec, Inc.
• ASB Industries, Inc.
• American Roller Company