Thermal Spray Global Market Report 2024

The thermal spray market size has grown strongly in recent years. It will grow from $10.73 billion in 2023 to $11.42 billion in 2024 at a compound annual growth rate (CAGR) of 6.5%. The growth observed in the historical period can be attributed to several factors. These include advancements in aerospace engineering, increased demands from the automotive industry, innovations in medical implants, the need for improved efficiency in power generation, requirements for corrosion resistance, enhancements in material durability, and the rise of industrial automation.

The thermal spray market size is expected to see strong growth in the next few years. It will grow to $14.82 billion in 2028 at a compound annual growth rate (CAGR) of 6.7%. The anticipated growth in the forecast period can be attributed to several key factors. These include advancements in material science leading to improved coating technologies, increased demand for surface coatings in aerospace and automotive industries for enhanced performance and durability, rising adoption of thermal spray in healthcare for medical devices, and growth in the renewable energy sector driving demand for corrosion-resistant coatings. Additionally, technological innovations are expected to play a significant role in driving growth, along with stringent environmental regulations necessitating the use of eco-friendly coating processes. Major trends expected during this period include advancements in coating materials technology, a rise in the use of plasma spray techniques for improved coating quality and efficiency, expansion into emerging markets, heightened emphasis on eco-friendly processes to reduce environmental impact, and greater integration with digital manufacturing and automation technologies to enhance production efficiency.

The thermal spray market is anticipated to experience significant growth, driven by the expanding energy and power industries. These industries encompass a wide range of sectors involved in generating, transmitting, and utilizing energy resources to meet societal needs. The growth in energy and power sectors is attributed to factors such as increasing global electricity demand, advancements in renewable energy technologies, and the shift towards cleaner and more sustainable energy sources. Thermal spray coatings play a crucial role in these industries by enhancing turbine efficiency, extending equipment lifespan, and combating corrosion in various components. For example, in 2022, the electricity, gas, steam, and air conditioning supply industry recorded a substantial turnover of £22 billion ($31.02 billion), representing 31.7% of the total turnover in the low carbon and renewable energy economy. This sector witnessed a notable increase of 59.6% (£8.2 billion ($11.562 billion)) from 2021 to 2022, as reported by the Office for National Statistics. Thus, the burgeoning energy and power industries are poised to propel the thermal spray market forward.

Key players in the thermal spray market are dedicated to developing cutting-edge solutions to enhance coating quality, boost productivity, and address evolving industry needs. One such innovation is supersonic spraying technology, where particles are accelerated to velocities surpassing the speed of sound, resulting in high-quality coatings and improved efficiency. For instance, Castolin Eutectic introduced the XupersoniClad, a thermal spraying service utilizing supersonic spraying technology. This service offers an efficient solution for new-generation high entropy alloy (HEA) coatings, which combine multiple elements to outperform traditional materials. Operating at lower temperatures and higher velocities compared to traditional methods, this warm spray process enhances effectiveness and efficiency.

In December 2023, Kymera International acquired Metallisation Ltd, aiming to strengthen its surface technologies division and expand its thermal spray solutions. This strategic move positions both companies as global leaders in thermal spray applications, particularly in the UK and European regions. By leveraging their combined strengths, Kymera International and Metallisation Ltd seek mutual growth and benefit in the 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, Hunter Chemical LLC, Thermion Inc., C&M Technologies GmbH, Supersonic Spray Technologies, Metallizing Equipment Co. Pvt. Ltd.

North America was the largest region in the thermal spray market in 2023. Asia-Pacific is expected to be the fastest-growing region in the forecast period. The regions covered in the thermal spray market report are Asia-Pacific, Western Europe, Eastern Europe, North America, South America, Middle East, Africa.

The countries covered in the thermal spray market report are Australia, Brazil, China, France, Germany, India, Indonesia, Japan, Russia, South Korea, UK, USA, Canada, Italy, Spain.

Thermal spray is a coating process wherein molten or semi-molten materials are sprayed onto a surface to create a protective or decorative layer. This process aims to enhance surface properties such as wear resistance, corrosion protection, and thermal insulation, ultimately prolonging the lifespan of components, improving their performance, and reducing maintenance costs.

The primary product types within the thermal spray industry include coatings and materials. Coatings are applied to surfaces for protection, decoration, or functional purposes. Various technologies, such as cold spray, flame spray, plasma, and spray, are utilized across a wide range of end-user industries including aerospace, industrial gas turbine, automotive, electronics, oil and gas, medical devices, and energy and power.

The thermal spray research report is one of a series of new reports that provides thermal spray market statistics, including the thermal spray industry's global market size, regional shares, competitors with a thermal spray market share, detailed thermal spray market segments, market trends and opportunities, and any further data you may need to thrive in the thermal spray industry. This thermal spray market research report delivers a complete perspective of everything you need, with an in-depth analysis of the current and future scenarios of the industry.

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.

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.


This product will be delivered within 3-5 business days.