Thermal Spray Global Market Report 2026

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.

Note that the outlook for this market is being affected by rapid changes in trade relations and tariffs globally. The report will be updated prior to delivery to reflect the latest status, including revised forecasts and quantified impact analysis. The report's Recommendations and Conclusions sections will be updated to give strategies for entities dealing with the fast-moving international environment.

Tariffs have influenced the thermal spray market by increasing costs of imported spray powders, specialty alloys, ceramic materials, and advanced spray equipment. These impacts are most visible in aerospace, automotive, and energy sectors across north america, europe, and asia pacific, where global sourcing of high performance materials is common. Higher costs have affected capital investments and project timelines. However, tariffs have promoted domestic production of spray materials, regional equipment manufacturing, and localized service capabilities, enhancing long term market resilience and supply security.

The thermal spray market research report is one of a series of new reports from The Business Research Company that provides thermal spray market statistics, including thermal spray industry 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 scenario of the industry.

The thermal spray market size has grown strongly in recent years. It will grow from $12.11 billion in 2025 to $12.81 billion in 2026 at a compound annual growth rate (CAGR) of 5.8%. The growth in the historic period can be attributed to demand for component life extension, growth of aerospace manufacturing, use in oil and gas equipment protection, adoption in industrial machinery maintenance, development of advanced spray technologies.

The thermal spray market size is expected to see strong growth in the next few years. It will grow to $15.94 billion in 2030 at a compound annual growth rate (CAGR) of 5.6%. The growth in the forecast period can be attributed to increasing demand for lightweight durable components, growth in electric vehicle manufacturing, expansion of power generation infrastructure, advancements in spray materials, rising automation in coating processes. Major trends in the forecast period include rising adoption of thermal spray for wear resistant coatings, growing use in aerospace and automotive components, increasing demand for corrosion protection solutions, expansion of thermal barrier coatings in energy systems, higher integration of automated thermal spray equipment.

The growing energy and power industries are expected to drive the thermal spray market going forward. Energy and power industries include sectors involved in generating, transmitting, distributing, and utilizing energy resources to meet various societal needs. These industries are expanding due to rising global electricity demand, advancements in renewable energy technologies, and ongoing efforts to transition to cleaner and more sustainable energy sources. The energy and power sector uses thermal spray coatings to improve turbine efficiency, extend equipment lifespan, and reduce corrosion in multiple components. For instance, in July 2025, according to the Office for National Statistics (ONS), a UK-based national statistical institute, in 2023, the electricity, gas, steam, and air conditioning supply industry within the UK low carbon and renewable energy economy (LCREE) reported a turnover of £20.2 ($23.46) billion. Therefore, the expanding energy and power industries are driving the thermal spray market.

Major companies in the thermal spray market are focused on developing advanced solutions, such as supersonic spraying technology, to improve coating quality, enhance productivity, and address emerging industry challenges. Supersonic spraying technology in thermal spray refers to a process where particles are accelerated to velocities exceeding the speed of sound, resulting in high coating quality and increased efficiency. For instance, in June 2023, Castolin Eutectic, a Germany-based company that provides surface protection solutions, launched the XupersoniClad, a new thermal spraying service that leverages supersonic spraying technology. This service is designed to provide an effective solution for new-generation high entropy alloy (HEA) coatings, which combine five or more elements to outperform traditional materials. It is a warm spray process that operates at lower temperatures and higher velocities than traditional high-velocity oxy-fuel (HVOF) processes, making it more efficient and effective.

In December 2023, Kymera International, a US-based industrial coating manufacturing company, acquired Metallisation Ltd for an undisclosed amount. This strategic acquisition aims to bolster Kymera's surface technologies division by expanding its thermal spray solutions, positioning both companies as global leaders in thermal spray applications, particularly in the UK and European regions, and leveraging their combined strengths for mutual benefit and growth. Metallisation Limited is a UK-based supportive coating manufacturing company that manufactures thermal and metal spray equipment.

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, C&M Technologies GmbH, Supersonic Spray Technologies, Metallizing Equipment Co. Pvt. Ltd

North America was the largest region in the thermal spray market in 2025. 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, South East Asia, 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, Taiwan, Russia, South Korea, UK, USA, Canada, Italy, Spain

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.

Thermal Spray Market Global Report 2026 from The Business Research Company provides strategists, marketers and senior management with the critical information they need to assess the market.

This report focuses thermal spray market which is experiencing strong growth. The report gives a guide to the trends which will be shaping the market over the next ten years and beyond.

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Where is the largest and fastest growing market for thermal spray ? How does the market relate to the overall economy, demography and other similar markets? What forces will shape the market going forward, including technological disruption, regulatory shifts, and changing consumer preferences? The thermal spray market global report from the Business Research Company answers all these questions and many more.

The report covers market characteristics, size and growth, segmentation, regional and country breakdowns, total addressable market (TAM), market attractiveness score (MAS), competitive landscape, market shares, company scoring matrix, trends and strategies for this market. It traces the market's historic and forecast market growth by geography.

• The market characteristics section of the report defines and explains the market. This section also examines key products and services offered in the market, evaluates brand-level differentiation, compares product features, and highlights major innovation and product development trends.
• The supply chain analysis section provides an overview of the entire value chain, including key raw materials, resources, and supplier analysis. It also provides a list competitor at each level of the supply chain.
• The updated trends and strategies section analyses the shape of the market as it evolves and highlights emerging technology trends such as digital transformation, automation, sustainability initiatives, and AI-driven innovation. It suggests how companies can leverage these advancements to strengthen their market position and achieve competitive differentiation.
• The regulatory and investment landscape section provides an overview of the key regulatory frameworks, regularity bodies, associations, and government policies influencing the market. It also examines major investment flows, incentives, and funding trends shaping industry growth and innovation.
• The market size section gives the market size ($b) covering both the historic growth of the market, and forecasting its development.
• The forecasts are made after considering the major factors currently impacting the market. These include the technological advancements such as AI and automation, Russia-Ukraine war, trade tariffs (government-imposed import/export duties), elevated inflation and interest rates.
• The total addressable market (TAM) analysis section defines and estimates the market potential compares it with the current market size, and provides strategic insights and growth opportunities based on this evaluation.
• The market attractiveness scoring section evaluates the market based on a quantitative scoring framework that considers growth potential, competitive dynamics, strategic fit, and risk profile. It also provides interpretive insights and strategic implications for decision-makers.
• Market segmentations break down the market into sub markets.
• The regional and country breakdowns section gives an analysis of the market in each geography and the size of the market by geography and compares their historic and forecast growth.
• Expanded geographical coverage includes Taiwan and Southeast Asia, reflecting recent supply chain realignments and manufacturing shifts in the region. This section analyzes how these markets are becoming increasingly important hubs in the global value chain.
• The competitive landscape chapter gives a description of the competitive nature of the market, market shares, and a description of the leading companies. Key financial deals which have shaped the market in recent years are identified.
• The company scoring matrix section evaluates and ranks leading companies based on a multi-parameter framework that includes market share or revenues, product innovation, and brand recognition.

Scope

• Markets Covered:1) By Product Type: Coatings; Materials; Thermal Spray Equipment
• 2) By Technology: Cold Spray; Flame Spray; Plasma
• 3) By End-User Industry: Aerospace; Industrial Gas Turbines; Automotive; Electronics; Oil And Gas; Medical Devices; Energy And Power
• Subsegments:
• 1) By Coatings: Ceramic Coatings; Metal Coatings; Composite Coatings; Carbide Coatings; Zinc And Aluminum Coatings (For Corrosion Protection); Thermal Barrier Coatings; Wear-Resistant Coatings; Anti-Friction Coatings
• 2) By Materials: Powder Materials (Metal; Ceramic; Alloy Powders); Wire Materials (Metal Wires For Spray Coating); Rod Materials (For Specific Thermal Spraying Techniques); Bonding Materials (Primers And Adhesives); Gas And Liquid Fuels (Used For Thermal Spray Processes)
• 3) By Thermal Spray Equipment: Spray Guns (Plasma Spray Guns; Hvof Guns); Plasma Spray Equipment; Flame Spray Equipment; High-Velocity Oxygen Fuel (Hvof) Equipment; Arc Spray Systems; Wire Feeders; Powder Feeders; Control And Monitoring Systems For Thermal Spraying
• Companies Mentioned: 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; C&M Technologies GmbH; Supersonic Spray Technologies; Metallizing Equipment Co. Pvt. Ltd
• Countries: Australia; Brazil; China; France; Germany; India; Indonesia; Japan; Taiwan; Russia; South Korea; UK; USA; Canada; Italy; Spain
• Regions: Asia-Pacific; South East Asia; Western Europe; Eastern Europe; North America; South America; Middle East; Africa
• Time Series: Five years historic and ten years forecast.
• Data: Ratios of market size and growth to related markets, GDP proportions, expenditure per capita,
• Data Segmentations: country and regional historic and forecast data, market share of competitors, market segments.
• Sourcing and Referencing: Data and analysis throughout the report is sourced using end notes.
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