Thermal Spray Equipment Market Size
Thermal Spray Equipment Market Overview
| Study Period | 2019 - 2030 |
| Market Size (2025) | USD 434.59 Million |
| Market Size (2030) | USD 557.57 Million |
| Growth Rate (2025 - 2030) | 5.11% CAGR |
| Fastest Growing Market | Asia Pacific |
| Largest Market | Asia-Pacific |
| Market Concentration | High |
Major Players
*Disclaimer: Major Players sorted in no particular order |
Thermal Spray Equipment Market Analysis
The Thermal Spray Equipment Market size is estimated at USD 434.59 million in 2025, and is expected to reach USD 557.57 million by 2030, at a CAGR of 5.11% during the forecast period (2025-2030).
The thermal spray equipment industry is experiencing significant transformation driven by technological advancements and the integration of automation. Advanced robotics and computer-integrated systems are increasingly being deployed to enhance coating precision and consistency, particularly in high-precision applications. The industry has witnessed substantial progress in cold spray equipment technology, with improvements in nozzle design, powder quality, and process optimization leading to enhanced coating performances. This technological evolution has enabled manufacturers to achieve highly dense coatings through extreme velocity-induced plastic deformation of coating material particles.
The industry is witnessing a notable shift towards more sustainable and environmentally conscious coating solutions. The emergence of solution precursor plasma spraying (SPPS) as an innovative coating deposition method has gained significant traction, offering advantages in producing nanostructured coatings with enhanced properties. According to industry data, over 30 manufacturers of wind turbines now utilize thermal spray equipment zinc or zinc-aluminum alloy coatings for corrosion protection, demonstrating the growing adoption of these technologies in renewable energy applications.
The market is experiencing diversification in application areas beyond traditional sectors. The twin wire-arc thermal spray equipment systems are gaining prominence due to their superior properties and cost-effectiveness, offering advantages such as low heat input, high bond strengths, and the ability to spray thicker coatings. The global electricity demand is projected to grow by 2.7% annually during 2022-2024, with renewables expected to grow by 8% per year, serving more than 90% of net demand growth, indicating expanding opportunities for industrial coating equipment in the power generation sector.
The industry is witnessing significant developments in HVOF (High-Velocity Oxygen Fuel) coating technologies as an alternative to traditional chrome plating. This shift is driven by environmental regulations and superior performance characteristics, including better wear resistance and longer overhaul cycles. Boeing's estimate of delivering 43,610 commercial aircraft by 2040 with a 3.1% growth rate indicates substantial long-term opportunities for plasma spray equipment in the aerospace sector. The wind energy sector's expected achievement of 1 TW installed capacity by 2025 further demonstrates the expanding application scope for spray coating systems across various industrial sectors.
Thermal Spray Equipment Market Trends
Rising Application in Aerospace Industry
The aerospace industry represents one of the most significant growth drivers for thermal spray equipment, with applications spanning critical components like jet engine parts, landing gear, and structural elements. Thermal spray coatings are extensively utilized in crucial applications such as rocket combustion chambers, compressor air seals, and high-pressure nozzles, where specialized coatings of chromium cobalt, aluminum oxide, and chromium carbide are employed for enhanced performance and durability. The increasing demand for new aircraft, driven by rising air travel and fleet modernization needs, has created substantial opportunities for thermal spray equipment manufacturers. According to Boeing Commercial Outlook 2022-2041, the global forecast for commercial aviation services, including maintenance and engineering operations, is projected to reach USD 3,615 billion by 2041, indicating massive potential for thermal spray applications.
The aerospace sector's shift towards more efficient and environmentally friendly coating solutions has further accelerated the adoption of thermal spray equipment. Boeing's leadership in implementing thermal spray equipment as an alternative for hard chromium plating on numerous structural components has set an industry-wide precedent. This transition is supported by the projected growth in the global airplane fleet size, expected to expand from approximately 25,900 units in 2019 to 47,080 units by 2041. The substantial order backlog and manufacturers' push to accelerate production, evidenced by the projected delivery of 41,170 new airplanes by 2041, further reinforce the crucial role of thermal spray equipment in meeting industry demands for high-performance coating solutions.
Rising Popularity of Thermal Spray Ceramic Coatings
Thermal spray ceramic coatings have emerged as a crucial technology across various industrial applications, offering superior protection against wear, corrosion, and thermal degradation. These coatings are increasingly preferred in high-performance applications due to their ability to provide exceptional surface properties while maintaining the base material's structural integrity. The versatility of ceramic coatings, particularly in applications requiring high-temperature resistance and wear protection, has led to their widespread adoption in industries ranging from automotive manufacturing to power generation equipment. The technology's ability to apply coatings with precise thickness control and excellent adherence to substrates has made it an indispensable solution for manufacturers seeking to enhance component longevity and performance.
The automotive sector, particularly the growing electric vehicle (EV) segment, has become a significant driver for ceramic coating equipment adoption. The technology's capability to provide thermal management solutions and wear resistance has proven essential for EV components, where thermal efficiency and durability are critical factors. The steel industry has also embraced ceramic coating equipment for protecting processing rolls, utilizing various methods including HVOF, spray fusing, and plasma spraying. This widespread adoption across diverse industrial applications has created a robust demand for industrial spraying equipment, as manufacturers seek to implement these advanced coating solutions in their production processes.
Evolution in Power Generation Sector
The power generation sector's ongoing transformation has created significant opportunities for industrial spraying equipment applications, particularly in protecting critical components exposed to extreme operating conditions. Thermal spray coatings play a vital role in enhancing the durability and efficiency of power generation equipment, from turbine components to boiler tubes and heat exchangers. The technology's ability to provide thermal barrier coatings and corrosion protection has become increasingly important as power plants strive to improve operational efficiency and extend equipment lifespan. These applications have become particularly crucial in both conventional and renewable energy facilities, where component reliability directly impacts plant performance and maintenance schedules.
The sector's evolution towards more efficient and sustainable power generation methods has further expanded the applications for surface coating equipment. The technology's versatility in applying specialized coatings that can withstand high temperatures, corrosive environments, and mechanical stress has made it an essential tool in modern power plant maintenance and construction. Thermal spray coatings are extensively used in protecting critical components such as gas turbine parts, steam turbine components, and various other power generation equipment, contributing to improved operational efficiency and reduced maintenance requirements. This trend is particularly significant as the power generation sector continues to adapt to changing energy demands and environmental requirements, driving the need for more advanced coating solutions.
Segment Analysis: Product Type
Spray Guns and Nozzles Segment in Thermal Spray Equipment Market
The spray guns and nozzles segment dominates the global thermal spray equipment market, commanding approximately 30% of the total market share in 2024. This segment's prominence is driven by its critical role in various thermal spray applications across aerospace, automotive, and industrial sectors. The segment's leadership position is reinforced by continuous technological advancements in spray gun system designs that enhance coating efficiency and quality. Manufacturers are increasingly focusing on developing advanced spray guns with improved particle velocity control and better thermal management capabilities. The segment's growth is particularly strong in aerospace applications, where high-performance coatings are essential for turbine components and landing gear. Additionally, the rising adoption of thermal spray coatings in medical device manufacturing and power generation sectors has further strengthened this segment's market position.
Remaining Segments in Product Type
The thermal spray equipment market encompasses several other significant segments, including thermal spray coating systems, dust collection equipment, feeder equipment, spare parts, and noise-reducing enclosures. Thermal spray coating systems play a vital role in providing complete coating solutions for industrial applications. Dust collection equipment has become increasingly important due to stricter environmental regulations and workplace safety requirements. Feeder equipment ensures precise material delivery during the coating process, while spare parts support the maintenance and continuous operation of thermal spray systems. Noise-reducing enclosures have gained prominence due to a growing emphasis on workplace safety and noise pollution control. Each of these segments contributes uniquely to the overall thermal spray ecosystem, serving different aspects of the coating process and meeting specific industry requirements.
Segment Analysis: Process
Electric Energy Segment in Thermal Spray Equipment Market
The Electric Energy segment dominates the global thermal spray equipment market, commanding approximately 56% of the total market share in 2024. This segment encompasses key technologies including wire arc, plasma, and cold spray processes, with plasma spray being particularly prominent due to its versatility in spraying almost all types of coating materials, including ceramics, metals, and polymers. The segment's leadership position is primarily driven by its lower power requirements of only 5-10kW compared to 50kW for plasma and HVOF spraying systems, making it more energy-efficient and cost-effective. Additionally, the electric energy process offers advantages such as little to no heat transfer to the substrate, higher spray rates, and some of the fastest coating rates of any coating method, making it particularly attractive for industries requiring high-volume production capabilities.
Combustion Segment in Thermal Spray Equipment Market
The Combustion segment represents a significant portion of the thermal spray equipment market, encompassing both low-velocity and high-velocity (HVOF/HVLF/HVAF) processes. This segment includes various technologies such as flame powder spraying, flame wire spraying, and detonation processes. Low-velocity combustion systems are particularly valued for their economic advantages and versatility in low-temperature applications, while high-velocity systems like HVOF spray equipment are gaining prominence for their ability to produce extremely dense coatings with superior bond strength. The segment's growth is supported by its wide range of applications across industries, from automotive and aerospace to oil and gas, where these systems provide critical surface protection and enhancement capabilities.
Segment Analysis: End-User Industry
Aerospace Segment in Thermal Spray Equipment Market
The aerospace segment dominates the global thermal spray equipment market, holding approximately 38% market share in 2024, while also demonstrating the strongest growth trajectory through 2024-2029. This segment's prominence is driven by the extensive application of thermal spray equipment in protecting engine turbine blades from extreme temperatures and ensuring increased reliability for extended periods. In aircraft engines, more than hundreds of key components require thermal spray coatings, including actuation systems, auxiliary power unit components, environmental control components, landing gear components, propulsion structures, slat and flap tracks, starter components, wing components, wheel bearing fits, shrouds, blades, combustors, augmentor liners and baskets, flanges, stators, mid spams, and bearing journals. The increasing demand for new aircraft, driven by growing passenger volumes and rising aircraft retirements, continues to fuel the demand for thermal spray equipment in this sector. Additionally, the aerospace industry's focus on improving fuel efficiency and reducing maintenance costs through advanced coating technologies further strengthens this segment's market position.
Remaining Segments in End-User Industry
The thermal spray equipment market serves several other crucial industry segments, including industrial gas turbines, automotive, electronics, oil and gas, medical devices, and energy and power sectors. The industrial gas turbines segment benefits from the increasing demand for improved thermal efficiency and reduced emissions in power generation applications. The automotive sector utilizes thermal spray equipment for coating engine components and improving wear resistance. In the electronics industry, thermal spray equipment finds applications in providing dielectric coatings and electromagnetic shielding. The oil and gas sector employs these systems for protecting components against corrosion and wear in challenging environments. The medical devices segment utilizes thermal spray equipment for biocompatible coatings on implants and surgical instruments, while the energy and power sector applies these systems in various turbine components and boiler tubes for enhanced performance and longevity.
Thermal Spray Equipment Market Geography Segment Analysis
Thermal Spray Equipment Market in Asia-Pacific
The Asia-Pacific region represents a dominant force in the global thermal spray equipment market, driven by rapid industrialization and technological advancements across multiple sectors. The region's market landscape is characterized by strong manufacturing bases in China, Japan, and South Korea, complemented by emerging economies like India and the ASEAN countries. The presence of major aerospace, automotive, and electronics manufacturing hubs, particularly in China and Japan, has created substantial demand for thermal spray equipment. The region's growth is further supported by increasing investments in industrial infrastructure and the adoption of advanced coating technologies across various end-user industries.
Thermal Spray Equipment Market in China
China dominates the Asia-Pacific thermal spray equipment market, holding approximately 35% of the regional market share. The country's market leadership is driven by its extensive manufacturing capabilities and robust industrial base. China's thermal spray equipment sector benefits from significant investments in aerospace manufacturing, with the presence of over 200 small aircraft parts manufacturers concentrated in major industrial hubs like Nanchang, Shanghai, and Chengdu. The country's commitment to technological advancement, particularly in the electronics and automotive sectors, further strengthens its market position. The government's focus on developing high-tech industries and improving manufacturing capabilities continues to drive demand for advanced coating solutions.
Thermal Spray Equipment Market in ASEAN Countries
The ASEAN countries represent the fastest-growing market in the Asia-Pacific region, with a projected growth rate of approximately 6% from 2024-2029. This growth is primarily driven by increasing industrialization and foreign direct investment in countries like Thailand, Vietnam, and Malaysia. The region's expanding electronics manufacturing sector, which accounts for nearly 30-35% of total exports, creates substantial demand for thermal spray equipment. The automotive sector's growth, particularly in Thailand and Indonesia, coupled with increasing investments in aerospace and medical device manufacturing, further accelerates market expansion. The region's strategic focus on developing high-tech manufacturing capabilities and improving industrial infrastructure continues to create new opportunities for industrial coating equipment manufacturers.
Thermal Spray Equipment Market in North America
North America represents a mature and technologically advanced market for thermal spray equipment, characterized by high adoption rates of innovative coating technologies. The region's market is primarily driven by the United States, Canada, and Mexico, with strong demand from aerospace, automotive, and medical device industries. The presence of major aerospace manufacturers and extensive research and development activities in coating technologies contributes significantly to market growth. The region's focus on reducing environmental impact and improving coating efficiency has led to increased adoption of advanced spray coating systems.
Thermal Spray Equipment Market in United States
The United States leads the North American market, commanding approximately 79% of the regional market share. The country's dominant position is supported by its extensive aerospace industry, which is the largest globally. The presence of numerous thermal spray equipment manufacturers and strong research and development capabilities further strengthens its market leadership. The country's focus on developing advanced coating technologies for various applications, particularly in aerospace and medical devices, continues to drive market growth. The robust manufacturing infrastructure and stringent quality standards maintain the United States' position as a key market for metal spray equipment.
Thermal Spray Equipment Market in Canada
Canada emerges as the fastest-growing market in North America, with a projected growth rate of approximately 5% from 2024-2029. The country's growth is driven by its strong aerospace manufacturing sector, being the third-largest in civil aircraft production globally. Canada's strategic focus on developing advanced manufacturing capabilities and increasing investments in research and development contributes to market expansion. The country's growing emphasis on sustainable coating technologies and increasing adoption of thermal spray systems in various industrial applications continues to drive market growth.
Thermal Spray Equipment Market in Europe
The European thermal spray equipment market demonstrates strong technological capabilities and innovation in coating solutions. The region's market is characterized by the presence of established manufacturers in Germany, the United Kingdom, France, and Italy. The strong focus on research and development, particularly in advanced coating technologies, drives market growth. The region's robust automotive and aerospace sectors, coupled with increasing adoption of industrial coating equipment in medical device manufacturing, creates sustained demand for coating solutions.
Thermal Spray Equipment Market in Germany
Germany stands as the largest market for thermal spray equipment in Europe, driven by its strong industrial base and technological leadership. The country's market is supported by the presence of over 2,300 aerospace firms and extensive production bases for aircraft components. Germany's commitment to industrial innovation and high-quality manufacturing standards maintains its position as a key market. The country's strong automotive sector and increasing focus on advanced coating technologies further reinforce its market leadership.
Thermal Spray Equipment Market in Germany - Growth Prospects
Germany also leads the European market in terms of growth potential, driven by continuous technological advancements and increasing industrial applications. The country's focus on Industry 4.0 initiatives and automation in manufacturing processes creates new opportunities for thermal spray equipment adoption. The growing emphasis on sustainable coating solutions and increasing investments in research and development support market expansion. Germany's strong manufacturing ecosystem and commitment to technological innovation continue to drive market growth.
Thermal Spray Equipment Market in South America
The South American thermal spray equipment market shows steady development, with Brazil and Argentina as key markets. The region's growth is driven by increasing industrialization and growing adoption of advanced coating technologies in various sectors. Brazil emerges as both the largest and fastest-growing market in the region, supported by its robust aerospace and automotive industries. The region's focus on improving manufacturing capabilities and increasing investments in industrial infrastructure creates opportunities for market expansion.
Thermal Spray Equipment Market in Middle East & Africa
The Middle East & Africa region demonstrates growing potential in the thermal spray equipment market, with Saudi Arabia and South Africa as significant markets. The region's growth is driven by increasing investments in industrial infrastructure and growing adoption of advanced coating technologies. Saudi Arabia emerges as both the largest and fastest-growing market in the region, supported by its extensive oil and gas industry and growing industrial diversification efforts. The region's focus on developing manufacturing capabilities and increasing industrial automation creates new opportunities for market expansion.
Thermal Spray Equipment Industry Overview
Top Companies in Thermal Spray Equipment Market
The thermal spray equipment market is characterized by continuous product innovation, with leading companies focusing on developing advanced coating technologies and automated systems. Companies are investing significantly in research and development to enhance equipment efficiency, precision, and coating quality while reducing operational costs. Strategic partnerships and collaborations with end-user industries, particularly in the aerospace and automotive sectors, have become increasingly common to develop customized solutions. Market leaders are expanding their geographical presence through distribution networks and service centers, especially in emerging economies. The industry has witnessed a strong emphasis on developing environmentally friendly coating solutions and equipment that comply with stringent regulatory standards. Companies are also investing in digital technologies and automation capabilities to improve process control and consistency in thermal spray applications.
Consolidated Market Led By Global Players
The thermal spray equipment market exhibits a partially consolidated structure, with the top four players commanding a significant market share. These dominant players are primarily large, diversified industrial conglomerates with strong technological capabilities and extensive global presence. Companies like Oerlikon Metco, Linde, Kennametal, and GTV Verschleißschutz GmbH have established themselves through decades of expertise, robust distribution networks, and comprehensive product portfolios. The market has witnessed strategic acquisitions and partnerships aimed at expanding technological capabilities and geographical reach, particularly in high-growth regions.
The competitive landscape is characterized by high entry barriers due to significant capital requirements, technological expertise, and established customer relationships. Regional players and specialists focus on niche applications and local markets, while global leaders leverage their integrated operations across the value chain. The industry has seen increased collaboration between equipment manufacturers and coating material suppliers to provide complete solutions. Market participants are increasingly focusing on after-sales services and technical support to maintain a competitive advantage and customer loyalty.
Innovation and Service Drive Future Success
Success in the industrial coating equipment market increasingly depends on technological innovation, customization capabilities, and comprehensive service offerings. Companies need to invest in developing equipment that offers improved coating efficiency, reduced material waste, and enhanced process control. Building strong relationships with key end-user industries through technical collaboration and customized solutions is becoming crucial. Market players must also focus on developing cost-effective solutions while maintaining quality standards to address price sensitivity in emerging markets. The ability to provide integrated solutions, including equipment, materials, and technical support, will be a key differentiator.
Future market success will require companies to adapt to evolving industry requirements, particularly in terms of automation and digital integration. Players must strengthen their research and development capabilities to address specific application needs in growing sectors like medical devices and electronics. Environmental compliance and sustainability considerations will play an increasingly important role in equipment design and operation. Companies need to develop a strong local presence in key markets while maintaining global standards and support capabilities. The ability to provide comprehensive training and technical support will become more critical as equipment complexity increases. The integration of thermal spray system and spray coating system technologies will be pivotal in meeting these demands.
Thermal Spray Equipment Market Leaders
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Oerlikon
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Linde
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GTV Verschleibschutz GmbH
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Kennametal
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Saint-Gobain
- *Disclaimer: Major Players sorted in no particular order
Thermal Spray Equipment Market News
- December 2022: Oerlikon planned to invest in a new state-of-the-art assembly and production site for its surface solutions and equipment businesses in Switzerland.
- December 2021: Flame Spray Technologies BV introduced its new rGun, a rotating plasma gun thermal spray unit. This gun improves the capabilities of a standard plasma gun by providing continuous rotation of the attached plasma gun during the spray operation.
- September 2021: Lincotek launched an HMI technology-based thermal spray system which will improve the flexibility and usability of the thermal spray system.
Thermal Spray Equipment Industry Segmentation
Thermal Spray Equipment is used for thermal spray that consists of a heat source and a coating material in a powder or wire form, which is melted into microparticles and sprayed onto metal or sometimes plastic surfaces. The thermal spray equipment market is segmented by product type, process, end-user industry, and geography. By product type, the market is segmented into thermal spray coating systems, dust collection equipment, spray guns and nozzles, feeder equipment, spare parts, noise-reducing enclosures, and other product types. By process, the market is segmented into combustion and electric energy. By end-user industry, the market is segmented into aerospace, industrial gas turbines, automotive, electronics, oil and gas, medical devices, energy and power, and other end-user industries. The report also covers the market sizes and forecasts for the thermal spray equipment market in 15 countries across major regions. For each segment, the market sizing and forecasts have been done based on revenue (USD million).
| Product Type | Thermal Spray Coating Systems | ||
| Dust Collection Equipment | |||
| Spray Guns and Nozzles | |||
| Feeder Equipment | |||
| Spare Parts | |||
| Noise-reducing Enclosures | |||
| Other Product Types | |||
| Process | Combustion | ||
| Electric Energy | |||
| End-user Industry | Aerospace | ||
| Industrial Gas Turbines | |||
| Automotive | |||
| Electronics | |||
| Oil and Gas | |||
| Medical Devices | |||
| Energy and Power | |||
| Other End-user Industries | |||
| Geography | Asia-Pacific | China | |
| India | |||
| Japan | |||
| South Korea | |||
| ASEAN Countries | |||
| Rest of Asia-Pacific | |||
| North America | United States | ||
| Canada | |||
| Mexico | |||
| Europe | Germany | ||
| United Kingdom | |||
| France | |||
| Italy | |||
| Rest of Europe | |||
| South America | Brazil | ||
| Argentina | |||
| Rest of South America | |||
| Middle-East and Africa | Saudi Arabia | ||
| South Africa | |||
| Rest of Middle-East and Africa | |||
Thermal Spray Equipment Market Research Faqs
How big is the Thermal Spray Equipment Market?
The Thermal Spray Equipment Market size is expected to reach USD 434.59 million in 2025 and grow at a CAGR of 5.11% to reach USD 557.57 million by 2030.
What is the current Thermal Spray Equipment Market size?
In 2025, the Thermal Spray Equipment Market size is expected to reach USD 434.59 million.
Which is the fastest growing region in Thermal Spray Equipment Market?
Asia Pacific is estimated to grow at the highest CAGR over the forecast period (2025-2030).
Which region has the biggest share in Thermal Spray Equipment Market?
In 2025, the Asia-Pacific accounts for the largest market share in Thermal Spray Equipment Market.
What years does this Thermal Spray Equipment Market cover, and what was the market size in 2024?
In 2024, the Thermal Spray Equipment Market size was estimated at USD 412.38 million. The report covers the Thermal Spray Equipment Market historical market size for years: 2019, 2020, 2021, 2022, 2023 and 2024. The report also forecasts the Thermal Spray Equipment Market size for years: 2025, 2026, 2027, 2028, 2029 and 2030.
Our Best Selling Reports
Thermal Spray Equipment Industry Report
Mordor Intelligence offers a comprehensive analysis of the thermal spray equipment industry. We leverage decades of expertise in industrial technology research. Our extensive coverage includes the full range of plasma spray equipment, flame spray equipment, and arc spray equipment technologies. The report thoroughly examines industrial coating equipment applications. It provides a detailed analysis of powder spray equipment and cold spray equipment innovations. Our research methodology incorporates insights from leading manufacturers of ceramic coating equipment and metallization equipment.
Stakeholders gain valuable insights through our detailed examination of industrial spraying equipment trends and technological advancements in spray coating systems. The analysis covers emerging developments in metal spray equipment and specialized HVOF spray equipment applications. It also explores innovations in surface coating equipment technologies. Our comprehensive thermal spray system assessment is available as an easy-to-download report PDF. It features an in-depth analysis of spray gun systems and their industrial applications. The report provides actionable intelligence for manufacturers, suppliers, and end-users operating in the global industrial coating equipment market.
