Thermal Spray Equipment Market Size & Share 2026-2035

Thermal Spray Equipment Market Size

The global thermal spray equipment market size was estimated at USD 13.8 billion in 2025. The market is expected to grow from USD 14.5 billion in 2026 to USD 24.1 billion in 2035, at a CAGR of 5.8% according to latest report published by Global Market Insights Inc.

Thermal spray equipment is quickly becoming popular among many various types of industries, due to its ability to extend the life of an item while improving its performance. Thermal spray technology has an increasing number of applications across many industries including aerospace, automotive, energy, manufacturing, and heavy engineering, as they all rely on thermal spray equipment for providing protection for components that may experience extreme temperature, chemical or corrosive elements, and high friction levels.
 

Due to the individual industries utilizing machines and industrial systems that may be operating under higher levels of stress than they were in previous years, the requirement for producing enhanced protected coatings has grown tremendously, therefore requiring industries to be able to rely on higher-quality thermal spray systems in their manufacture and maintenance processes.
 

In addition, because of advancement made possible by research into materials science and the development of spray technologies, the application of thermal spray techniques is being pursued by many newer industries, including electronics and biomedical devices, as well as renewable energy. With the development of new application techniques and formulations, component manufacturers can have their products coated using thermal spray, providing additional protection and performance benefits while prolonging their useful lifespan.
 

In addition, modern multi-material spray systems continue to provide new avenues for industrial applications using thermal spray technology. As industrial manufacturers work to maximize efficiency in their operations while also providing consumers with more sustainable solutions and minimizing manufacturing downtime, manufacturers will begin to view thermal spray equipment as an important technology to support the continued growth of modern manufacturing.
 

Due to the global focus on improving equipment life and reducing maintenance costs there has been an increased demand for advanced materials designed to protect surfaces. Many parts manufactured for use in production undergo extreme wear, corrosion, oxidation and thermal stress; therefore, coated parts are essential to protecting them from such degradation. Coating technologies that employ thermal spray processes are an affordable option for significantly increasing the ability of a part to resist these types of damage. Due to their desire to reduce both operating interruptions and costly replacements, companies are utilizing surface protection technologies to enhance their productivity and the performance of their assets.
 

The increased number of environmental regulations, focused on decreased CO2 emissions and safer workplace practices, is pushing many businesses toward using less harmful, more ecologically friendly coating technologies. Thermal spray coating technology allows many industries to discontinue using less environmentally friendly coating processes such as hard chrome plating and instead use a safe and sustainable coating technology that doesn't sacrifice performance.
 

Thermal spray coating is also becoming increasingly more popular because of the increasing demand for renewable energy infrastructure, electric vehicles and the increased cost of operating high-efficiency equipment. As these industries continue to grow and require more sophisticated equipment, the demand for quality protective coatings will increase, which will make thermal spray systems an extremely important component of modern surface engineering practices.

Thermal Spray Equipment Market Trends

There is an increasing need for industrial coatings to be durable, efficient and provide advanced surface engineering solutions, which have led to the growth of the thermal spray equipment industries; along with this has come new advancements in technology, increased industrial use of thermal spray coating products and an increase in environmentally friendly coatings; these influences will continue to shape the future growth of this marketplace. The need for thermal spray coatings with higher performance characteristics within the aerospace, automobile, energy and major manufacturing industries has driven manufacturers to provide coatings that offer greater precision, automation, and versatility through thermal spray systems.
 

• Robotics automation is increasingly becoming commonplace for manufacturers due to their demand for consistent and high-quality coatings, while at the same time minimizing labor dependency and human error. With the help of robotic spray arms, automated process controls and digital monitoring systems to monitor process parameters, manufacturers can make fine adjustments to process parameters, apply a uniform thickness of coating and achieve repeatable results. This not only increases production efficiency but also assists in alleviating the current shortage of trained thermal spray technicians.
   
• Many industries are now moving to the use of high-performance materials like carbides, ceramics, and advanced alloys to protect the components operating in extreme environments. New formulations of materials, such as nanostructured powders and high-temperature ceramic blends, will allow for longer component life, higher wear resistance, and improved reliability. This trend is also being aided by new developments in material science that continue to increase the number of applications available for these new materials.
   
• In addition to the aerospace and automotive sectors, the use of thermal spray technology is becoming increasingly popular in several new industries, including the renewables, medical implant, and semiconductor industries. The renewables, medical implant, and semiconductor industries require a great deal of precision and specialization when applying coatings for temperature protection, biocompatibility and other requirements, making them ideal candidates for thermal spray technology as they continue to grow in demand within the global economy. These emerging industries are rapidly driving the need for more thermal spray equipment.
   
• As companies pursue sustainability initiatives, they are continuing to move away from the use of unsafe coating methods such as hard chrome plating to comply with strict environmental regulations. In addition to providing a safer and more sustainable alternative, thermal spray coatings can reduce emissions and produce less hazardous waste. In addition to meeting their environmental compliance requirements, companies who implement thermal spray technology can also reduce their overall ecological footprint and improve their image of sustainability with the public, allowing them to continue to gain a competitive advantage in the marketplace.
   

Thermal Spray Equipment Market Analysis

Based on equipment type, the thermal spray equipment market is divided into spray system, booths, dust collection systems, chillers, spray guns & nozzles, feeder systems, gas systems and others. In 2025, spray system motor held the major market share, generating a revenue of USD 3.6 billion.
 

• A spray system is a type of device used in thermal spray technology that is used to apply a protective coating onto an item using high-velocity heated material. This device has four main components: the spray gun, the feedstock delivery unit, the gas or power supply for creating heat and pressure for the spray gun, and the control systems.
   
• Spray systems can be powered by various forms of energy; for example, combustion, electrical, and plasma-powered spray systems create controlled environments so that the coating can be created with maximum density, adhesion, and durability. In other words, they provide very high temperatures at the point of operation, allowing for very tightly bonded coatings that enhance a component’s resistance to wear, corrosion, and temperature extremes.
   
• Modern spray systems have been developed to meet the demands of high precision and repeatability about the key parameters of particle velocity, spray angle, stand-off distance and heat input. As a result, there is a high level of consistency in the quality of coatings applied, even to difficult shapes or components that require close tolerances.
   
• Automation of robotic manipulator systems has allowed spray systems to provide consistent application and coverage of large areas with minimal exposure to human intervention. The new technology reduces mistakes and maximizes production efficiency while maintaining the ability to run continuously in a demanding industrial environment.
   
• Due to the versatility of spray systems and their adaptability for multiple coating applications, they are an essential option for many industries. Spray systems provide an essential service to the aerospace sector about the fabrication of turbine blades and landing gear; the automotive sector by providing a coating option for the fabrication of engine components; and the energy sector about coating boiler tubes and turbine parts as well as for the manufacture of molds and tools.
   
• As manufacturers strive for maximum efficiency, maximum life of their components and eco-friendly solutions to their coating needs, the use of spray systems also continues to expand in each industry. Because spray systems can be used to apply custom coatings designed to meet the individual environmental and mechanical needs of the component or part to be coated, they are an important technology in today's surface engineering world.
   

Based on surface type, the thermal spray equipment market is segmented into metals, ceramics, polymers, composites and others. The metals segment held the largest share, accounting for 41% of the global market in 2025.
 

• Metals coatings are thermal spraying processes utilizing metallic materials, for example, alloy, stainless steel, aluminum, nickel alloy, etc., to improve the performance of components in the various industries by providing enhanced performance characteristics to industrial components through thermal spraying processes. Due to their unique combination of durability, strength, and wear and corrosion resistance, metal-coated surfaces are chosen for many applications.
   
• When thermal spray is used to apply the metal coating, the sprayed coating creates a dense, uniform, bonded layer that improves the mechanical performance of the base material. The industry's many applications require metal-coated surfaces to withstand extreme operating conditions, including extreme temperatures, abrasives, and corrosive solutions.
   
• In many industrial applications, where components will be used under severe operating conditions, metal surface coatings are often applied to protect the underlying material from deterioration. High-temperature oxidation-resistant nickel and chromium alloy-coated components are well suited for use in high-temperature turbine and exhaust applications, or high-temperature heating equipment use.
   
• Metallic coating of steel or iron will resist wear on tools, shafts and rollers subjected to very abrasive conditions. Refurbishing worn parts with metallic coatings also allows manufacturers to refurbish and reuse these costly components, instead of replacing them completely. Therefore, this type of refurbishment provides improved cost efficiency and sustainability.
   
• With the advances made in thermal spray technologies, it is now possible to apply very thin layers of metal coating with an engineered multi-layer design. Together with this, the improved technology for thermal spray coatings has allowed for the creation of new and unique coatings using different types of metals in different combinations to achieve a variety of specific properties.
   
• As industries continue to require more efficient equipment that lasts longer, the metal surface type remains one of the largest and most widely used types of coatings on the thermal spray market. The combination of versatility and reliability has established this type of thermal spray coating as a constant in aerospace, automotive, power generation, manufacturing and repair industries.
   

Based on operation, the thermal spray equipment market is segmented into automatic, semi-automatic and manual. In 2025, automatic segment held the largest market share.
 

• Automatic thermal spray systems are considered the highest level of development and efficiency within the thermal spray equipment field. These systems are designed to provide excellent levels of consistency, precision, and throughput. These systems utilize robotic systems, programmable logic controllers (PLCs), and real-time monitor technology to perform an entire coating process with very little human operation.
   
• In addition, by automating this process, precise control can be achieved over the parameters for producing spray distance, temperature, feed rate, and motion path, etc., thus guaranteeing a uniform quality of the coatings produced across complex geometries. Due to the increasing demand for coatings to perform well within defined tolerances, the use of completely automated systems has become the preferred method of providing repeatability, minimizing errors, and maximizing productivity.
   
• In addition to reducing production line labor reliance and downtime, automatic systems help manufacturers who are struggling with workforce shortages or would like to standardize their manufacturing processes across multiple sites. Automatic systems improve production efficiency by providing a long-term cost-saving option through reducing the quantity of materials wasted during production, increased efficiency of energy utilization and reducing the amount of time that is spent reworking components.
   
• The trend toward digital manufacturing and the development of industry 4.0 technologies will continue to drive the need for automatic thermal spray systems and further reinforce their value proposition over manual or semi-automatic alternatives in today's surface engineering workflows.
   

North America Thermal Spray Equipment Market

In 2025, the U.S dominated the North America market, accounting for around 89% and generating around USD 3.3 billion revenue in the same year.
 

• The U.S. thermal spray equipment market is primarily driven by the U.S.'s advanced aerospace, defense, automotive and energy sectors, which heavily depend on high-performance coatings to provide improved durability and operational efficiency to their components. The U.S. has a well-established manufacturing ecosystem, which allows for innovation in robotic spray systems, digital monitoring technology, and advanced materials on to thermal spray processes. The focus on maintenance optimization, sustainability, and meeting strict environmental regulations creates additional demand for advanced spray equipment in the U.S.
   
• The market in North America has the advantage of very strong industrial activity in the three major North American regions and an extensive range of applications in aerospace, automotive, oil & gas, power generation, and heavy engineering. Increasingly, manufacturers in North America are utilizing more automated and/or high-efficiency systems to increase productivity and decrease operating expenses, which are important drivers of continuing growth within the market.
   
• In addition to having a strong supply chain, skilled workforce, and a significant presence of leading global thermal spray manufacturers and service providers in North America, technological advances in the market continue to occur. Furthermore, the continued increase in the amount of infrastructure development, increasing interest in refurbishing existing equipment, and expanding use of renewable energy technology are all helping to further increase the demand for thermal spray equipment in North America, making it one of the most dynamic regions for thermal spray equipment.
   

Europe Thermal Spray Equipment Market

Europe market held 22.5% share in 2025 and is expected to grow at 5.8% during the forecast period.
 

• The thermal spray equipment industry in Europe is heavily reliant on and thus will continue to see growth from industries like aerospace, automotive, energy and high-precision manufacturing. As a result, the OEMs and tier suppliers within these mature industries need repeatable quality, traceability and compliance, driving continued investments into automated spray cells, advanced process control and sophisticated dust collection and safety systems.
   
• The engineering culture throughout Europe is strongly established on having robust qualification protocols and multi-layer coating stacks specifically designed for turbine, drivetrain and tooling applications. There is strong and continued investment in refurbishing older components and extending the life of components, particularly within aerospace and power generation, thus maintaining a strong aftermarket and service market.
   
• Due to the evolving environmental framework and regulatory requirements in Europe, the equipment choice has also been affected. Users are moving toward more environmentally friendly combustion styles and implementing digital equipment monitoring to reduce waste and energy consumption as much as possible. Increasing electrification will create increased demand for lightweighting across multiple transportation platforms where thermal spray technology can address the tribological needs of electric powertrains. Consequently, more advanced equipment systems, as well as training and accreditation services, are becoming commonplace.
   

Asia Pacific Thermal Spray Equipment Market

The Asia Pacific leads the market with a share of around 31.6% in 2025 and is anticipated to grow with a CAGR of around 6.4% from 2026 to 2035.
 

• Throughout the course of global thermal spray equipment development and production, the APAC region has led the way in many areas, including a high rate of industrialization, a variety of manufacturing capabilities, and an abundance of parts produced in the aerospace, automotive and other industries. In addition to these factors, the existence of many manufacturing facilities concentrated in China, India, Japan, South Korea and the Southeast Asia has provided a significant level of demand for both robotics and high-volume products that can accept either metallic or ceramic materials.
   
• As MRO (Maintenance, Repair and Overhaul) and refurbishment are growing in APAC, there appears to be an increasing level of demand for portable and semi-auto equipment to facilitate MRO activities in the field, while factories across the region have embraced fully automated systems to produce a high degree of precision and throughput.
   
• Increased technology usage among manufacturers in the Asia Pacific region is accelerating due to the growing need for greater precision in tolerances, greater density of the coating being applied, and enhanced repeatability of the application process. Key areas of investment will be robotic manipulation, the integration of PLC/SCADA systems, real-time logging of application parameters, and artificial intelligence to assist with optimizing manufacturing processes to minimize waste due to rework or scrap material.
   
• The growth of many industries, i.e. renewable energy, oil/gas exploration, and semiconductor production will continue to create opportunities for high-performance coatings, such as thermal barrier, anti-corrosion, and anti-erosion coatings, in today's environment as equipment reliability and uptime are always crucial elements. APAC has maintained its dominance in the installed base and upgrade to next-generation spray equipment, with a larger percentage of its manufacturing activities occurring in North America, Europe, and China.
   

Latin America Thermal Spray Equipment Market

Latin America market is growing at a CAGR of 3% during the forecast period.
 

• The market in Latin America continues to grow, driven by growing demand from the mining, oil and gas, steelmaking, power generation and transportation sectors. Operators look to coating solutions to provide longer life cycles for components operating in some of the most difficult conditions, such as drill pipe, pump housings, rollers and turbine components. Ruggedized equipment and reliable feeders are available to meet this demand. Although one of the barriers for small businesses is the capital-intensive nature of thermal spray technology, regional service providers as well as maintenance repair and overhaul (MRO) shops help fill this gap by providing refurbishment programs along with semi-automated systems and supporting these activities with focused training.
   
• An overall operational theme from the contractors and operators is to have durable hydraulic motor configurations that require little to no maintenance costs after installation. As the fleets continue to age, so has the aftermarket for OEM replacement motors, seal kits, and filtration improvements. Ultimately, contractors and operators want Thermal Spray Equipment that allow for longer intervals between service, with decreased risk of failure or leaking fluids. With an increasing focus placed on energy efficiency, safety, and improved operating environments, there is also an increase in the number of variable-displacement hydraulic designs. By improving thermal management and allowing basic monitoring capabilities, this will help to expand their use. Hybrid electric/hydraulic technology is also beginning to come into play within industry. Hybrid designs provide additional fuel savings while reducing noise at a worksite, resulting in cost-effective solutions for many contractors and operators.
   

Thermal Spray Equipment Market Share

Linde is leading with 4% market share. Linde, Saint Gobain, Curtiss-Wright, Hoganas, Oerlikon collectively hold around 20%, indicating moderately fragmented market concentration. These prominent players are proactively involved in strategic endeavors, such as mergers & acquisitions, facility expansions & collaborations, to expand their product portfolios, extend their reach to a broad customer base, and strengthen their market position.
 

Aimtek company's primary responsibility in the thermal spray supply chain is to act as a manufacturer of consumables such as thermal spray powders, wires, and brazing alloys for MRO facilities and OEMs. Aimtek also manufactures thermal spray powder, brazing alloy, and wire for both OEMs and MROs. Through specialized application specific formulations to ensure quality and reliability of supply, Aimtek is a leading supplier of thermal spray materials for the coating needs of manufacturers.
 

Brycoat is a leader in offering precision coating processes including thermal spray, PVD, and CVD coatings. With a focus on applications where adhesion of coatings, surface finish and operational longevity are of utmost importance, Brycoat supports clients within the aerospace, medical devices, semi-conductor as well as other high-performance applications. Brycoat has extensive experience and knowledge that enables clients to extend the life and performance of their components by developing engineered solutions for their unique operational conditions.
 

Thermal Spray Equipment Market Companies

Major players operating in the thermal spray equipment industry are:

• A&A Thermal Spray Coatings
• Ador Fontech
• Aimtek
• Alloy Metal Surface Technologies
• Bodycote
• Brycoat
• Curtiss-Wright
• Hannecard Roller Coatings
• Hoganas
• Kennametal
• Lincoln Electric
• Linde
• Oerlikon
• Saint Gobain
• Wall Colmonoy
   

Linde has historically offered significant and reliable industry gas and engineered materials for thermal spray manufacturers complete, supported by stable, repeatable coating processes within their product line. Linde provides thermal spray manufacturers with specialized gas delivery solutions, premium metal & ceramic powders, and process optimization support, thus making Linde a preferred partner of the industries that utilize high-performance surface coatings. Linde's focus on precision, material purity, and process efficiency has allowed Linde to build a strong market presence in aerospace, energy, and high-end manufacturing applications.
 

Saint‑Gobain is among the largest producers of materials for thermal coating systems and produces a line of high-performance ceramic powders, including zirconia, alumina, and carbide blends. In addition to thermal coating applications, these materials are used in thermal-barrier, anti-wear, and corrosion-resistant coating applications for aerospace, automotive, and industrial uses. With a reputation for being one of the leading experts in the field of advanced materials, Saint-Gobain supplies its customers with engineered powders formulated specifically for use in Plasma Spray, HVOF, and other thermal coating processes to ensure that the products they produce will provide durable and reliable coating performance.
 

Thermal Spray Equipment Industry News

• In November 2025, Bodycote announced the successful Nadcap accreditation of its newly constructed 55,000 square foot Thermal Processing Facility located in Fairfield, Ohio. The facility has fully operational heat treat, vacuum brazing and TIG welding operations. Equipment at the site includes advanced vacuum furnaces, dedicated aluminum treatment lines and a high specification braze department to service the aerospace, defense and industrial OEM sectors. The facility will be at full production levels by January 2026.
   
• In August 2024, the introduction of an advanced plasma spray coating technology by Oerlikon Metco enables the coating to adhere better to components in industrial gas turbine applications, which leads to increased service life. This improvement is due to the optimization of particle velocities and improved stability for plume plasma spray and the ability to create coating technologies that provide strong high-density plating to Hot Zone Gas Turbines to meet the demands of extreme thermal cycles and oxidation resistance.
   
• In May 2023, Solar Turbines announced its acquisition of TSS, a company which provides specialized thermal spraying services like those offered by solar turbines in their aerospace segment. The acquisition of this division will allow solar turbines to enhance their competitive advantage in the U.S. Navy and commercial shipbuilding markets where both companies already operate. The acquisition also increases Solar Turbines' precision thermal spraying capabilities, including the addition of HVOF and plasma technologies into their thermal spraying division as well as increasing their product offerings for both defense and marine engine refurbishment programs.
   

The thermal spray equipment market research report includes in-depth coverage of the industry with estimates & forecasts in terms of revenue (USD Billion) & volume (Thousand Units) from 2022 to 2035, for the following segments:

Click here to Buy Section of this Report

Market, By Equipment Type

• Spray system
• Plasma
• Twin arc
• Flame spray
• HVOF
• Powder flame spray
• Others (vacuum, etc.)
• Booths
• Dust collection systems
• Chillers
• Spray guns and nozzles
• Feeder systems
• Gas systems
• Others (gas detection systems, etc.)

Market, By Surface Type

• Metals
• Ceramics
• Polymers
• Composites
• Others (e.g., carbides, oxides)

Market, By Operation

• Automatic
• Semi-automatic
• Manual

Market, By End Use Industry

• Aerospace
• Automotive
• Electronics
• Biomedical
• Manufacturing
• Oil and gas
• Energy and power
• Others (medical devices, etc.)

Market, By Distribution Channel

• Direct
• Indirect
   

The above information is provided for the following regions and countries:

North America

• U.S.
• Canada

Europe

• Germany
• UK
• France
• Italy
• Spain

Asia Pacific

• China
• India
• Japan
• Australia
• South Korea

Latin America

• Brazil
• Mexico
• Argentina

Middle East and Africa

• South Africa
• Saudi Arabia
• UAE