The global thermal spray coatings market reached a value of approximately USD 11.85 Billion in 2024. The market is projected to grow at a CAGR of 5.10% between 2025 and 2034, reaching a value of around USD 19.49 Billion by 2034.
Base Year
Historical Period
Forecast Period
According to the ITA, in 2022, the UK civil aerospace turnover totalled approximately USD 34.5 billion, boosting the thermal spray coatings market.
MHI forecasts India's auto industry to reach USD 179.68 billion by 2024, driving growth in the thermal spray coatings market.
According to the AIA, Aerospace and Defence contributed USD 391 billion to the US GDP, representing 1.7% of the total nominal GDP.
Compound Annual Growth Rate
5.1%
Value in USD Billion
2025-2034
Thermal Spray Coatings Market Outlook
*this image is indicative*
The thermal spray coatings market is propelled by the integration of automation and robotics in thermal spray processes which results in increasing precision, repeatability, and efficiency. Automated systems reduce labour costs and minimise human error, leading to higher-quality coatings.
Thermal spray coatings in aircraft engines enhance wear resistance, reduce oxidation, and improve thermal insulation. The expanding aerospace sector, notably driven by increased commercial air travel and defence expenditure, serves as a significant catalyst.
India witnessed a rise in the number of airports from 74 in 2014 to 147 in 2022, with projections indicating an increase to 220 by 2025.
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Growth in the power generation sector, rising industrial applications, environmental regulations and sustainability, and advancements in coating materials are the major trends impacting global thermal spray coatings market growth.
The power generation industry uses thermal spray coatings to protect equipment from corrosion and high temperatures. Further, the rise in the energy demand is driving the market growth.
Various industries such as oil and gas, healthcare, and electronics are increasingly adopting thermal spray coatings for their ability to improve component life and performance under harsh conditions.
Stricter environmental rules drive industries to embrace coatings that reduce emissions and energy use. Thermal spray coatings improve component efficiency and durability, reducing maintenance and replacement needs.
The development of new materials such as nanostructured coatings and carbide coatings provides superior performance characteristics. These materials offer enhanced hardness, wear resistance, and thermal stability.
The major developments propelling the demand for thermal spray coatings include the innovations in deposition techniques like HVOF, Cold Spray, and Plasma Spray have led to better coating adhesion, density, and uniformity. These technologies also allow for the application of coatings on complex geometries and sensitive substrates.
The adoption of digital technologies and Industry 4.0 principles is enhancing process control and monitoring. Real-time data collection, predictive maintenance, and simulation tools are improving the overall efficiency and effectiveness of thermal spray operations.
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“Global Thermal Spray Coatings Market Report and Forecast 2025-2034” offers a detailed analysis of the market based on the following segments:
Market Breakup by Technology
Market Breakup by Product Type
Market Breakup by Application
Market Breakup by Region
HVOF technology enhances the thermal spray coatings market by enabling rapid deposition rates and precise control over coating thickness, leading to increased productivity and reduced processing times for coating applications.
HVOF coatings typically have lower porosity and higher bond strength, reducing the risk of coating degradation and environmental contamination over time.
Electric arc spray coatings offer cost-effective solutions due to their relatively low equipment and operating costs compared to some other thermal spray methods. This affordability makes electric arc spray technology accessible to a wider range of industries and applications.
As air travel booms, the aerospace industry relies more heavily on thermal spray coatings to keep planes reliable, safe, and efficient, thus driving the thermal spray coatings market growth.
Aerospace manufacturers aim to lighten aircraft components for better fuel efficiency and cost-effectiveness. Thermal spray coatings provide this without compromising strength, aiding fuel savings.
Thermal spray coatings play a vital role in crafting drug delivery systems like inhalers, microneedles, and implantable drug-eluting devices. These coatings regulate release, bolster adherence, and elevate biocompatibility, improving targeted drug delivery efficacy.
North America holds a significant share of the thermal spray coatings market due to urbanisation and modernisation trends, alongside increasing disposable incomes. Demand from aerospace, oil and gas, and power generation industries, particularly for gas turbines, fuels this growth. Additionally, the United States government's policy transition towards replacing coal with natural gas for electricity generation is expected to further boost gas turbine demand.
Invest in Italy statistics reveal that Germany leads with 2,972 automotive sector companies, followed by Italy with 2,296, France with 1,908, Poland with 1,734, and Spain with 1,640. This indicates that Germany contributes the most to driving thermal spray coatings market demand, followed by Italy.
According to the Ministry of Petroleum and Natural Gas, GOI, the amount of natural gas produced in 2021-2022 was 34.02 BCM whereas it was 28.67 BCM in 2020-2021. This indicates the rise in the demand for the thermal spray coatings market in the country.
The companies are a provider of innovative processes, surface-enhancing materials, hard face welding, and other solutions to industries including ceramics, blasting, and others.
Founded in 1907 and based in Indianapolis, IN. The company provides surface-enhancing materials, innovative processes, technology, and more advanced coatings that extend the life of critical components.
Established in 1919 and based in West Springfield, Massachusetts. The company supplies thermal spray coating, hard face welding, and machining services for the protection of industrial machine components.
Founded in 1974 and based in San Diego, CA. The company has been a leader and innovator in the application of Thermal Sprayed Coatings.
Established in 1954 and is headquartered in Ernakulam, Kerala. CUMI Minerals provides correct solutions to various industries such as Abrasives, Refractories, Ceramics, Blasting, Metal Composites etc.
*Please note that this is only a partial list; the complete list of key players is available in the full report. Additionally, the list of key players can be customized to better suit your needs.*
Other global thermal spray coatings market key players are Metatech Thermal Spray Pvt. Ltd., Kennametal Inc., and Alloy Thermal Spray Pvt. Ltd. among others.
Thermal Spray Coatings Market Size
Thermal Spray Coatings Market Growth
Thermal Spray Coatings Market Trends
Thermal Spray Coatings Market Share
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The market was valued at USD 11.85 Billion in 2024.
The market is projected to grow at a CAGR of 5.10% between 2025 and 2034.
The revenue generated from the thermal spray coatings market is expected to reach USD 19.49 Billion in 2034.
The major market drivers are robust growth in the aerospace and automotive industry and an increase in usage in the healthcare industry.
The key market trends include increasing demand for ceramics in various industries and growing industrialisation.
The market is broken down into North America, Europe, Asia Pacific, Latin America, and Middle East and Africa.
The market is categorised according to the technology, which includes cold spray, flame spray, plasma spray, HVOF, electric arc spray, and others.
Based on the product type, the market is divided into metals, ceramics, intermetallic, polymers, carbides, abradable, and others.
Based on the application, the market is divided into aerospace, industrial gas turbine, automotive, medical, printing, oil and gas, steel, pulp and paper, and others.
The market key players are Praxair S.T. Technology, Inc., Hayden Corp, Flame Spray Coating Company, CUMI EMD., Metatech Thermal Spray Pvt. Ltd., Kennametal Inc., and Alloy Thermal Spray Pvt. Ltd. among others.
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