Thermal Spray Equipment Market Size by Types (Flame Spray, Electric Arc Wire Spray, Plasma Spray, Other), By Applications Covered (Aerospace, Industrial Gas Turbine, Automotive, Other) and Regional Forecast to 2033

Thermal Spray Equipment Market Size

The Global Thermal Spray Equipment market size was valued at USD 7.64 billion in 2024 and is projected to reach USD 8.12 billion in 2025, further advancing to USD 13.13 billion by 2033, showcasing a steady CAGR of 6.2% during the forecast period [2025–2033].

The US Thermal Spray Equipment market contributed nearly 28% of global revenue in 2025, driven by strong demand from aerospace, automotive, and power generation industries. Increasing adoption of coating technologies for turbine blades, engine parts, and industrial machinery has strengthened its market position. Additionally, rising investments in advanced plasma spray and high-velocity oxygen fuel (HVOF) systems are supporting innovation, with US manufacturers leading the development of next-generation equipment tailored for high-performance applications across defense, medical, and energy sectors.

Key Findings

• Market Size – Valued at USD 8.12 billion in 2025, expected to reach USD 13.13 billion by 2033, growing at a CAGR of 6.2%.

• Growth Drivers – 40% adoption in aerospace, 30% in turbines, 20% automotive demand, 10% medical and electronics expansion.

• Trends – 35% growth in automation, 25% modular design adoption, 20% Industry 4.0 integration, 20% eco-friendly system upgrades.

• Key Players – Oerlikon, Praxair Surface Technologies, Metallisation, Matrasur Composites, Sprimag.

• Regional Insights – Asia-Pacific 35%, North America 30%, Europe 25%, Middle East & Africa 10% market share.

• Challenges – 30% cost rise in feedstock, 25% maintenance expense hike, 20% regulatory compliance costs, 25% energy consumption growth.

• Industry Impact – 40% efficiency gain in aerospace, 30% savings in turbines, 20% lifecycle extension in automotive, 10% boost in medical devices.

• Recent Developments – 25% improvement in cold spray, 20% higher deposition efficiency, 20% modular upgrades, 20% cost-saving HVOF, 15% robotic automation gains.

The Thermal Spray Equipment Market continues to play a critical role in high-performance surface engineering. The market commands a strong niche, contributing approximately 12–14% of the industrial wear‑resistant and surface engineering tools segment, while capturing 18–20% within aerospace and defense deposition tasks Spray systems alone accounted for 44% of the segment value in 2025, reflecting the dominance of power and powder delivery in coatingsWith rising demand from aerospace, energy, automotive, and electronics sectors, the Thermal Spray Equipment Market Market remains fundamental to enhancing component durability, corrosion protection, and operational longevity.

Thermal Spray Equipment Market Trends 

The Thermal Spray Equipment Market Market is being reshaped by technological innovation and expanding industrial adoption. Spray systems, accounting for 44% of the market in 2025, remain dominant due to their versatility in delivering a broad range of materials.Within the industrial wear-resistant and surface engineering tools market, thermal spray tools hold 12–14%, underscoring their significance in replacing overlays and plating methods. In aerospace and defense, the Thermal Spray Equipment Market Market contributes 18–20%, driven by the need for thermal barrier, anti‑wear, and anti‑oxidation coatings on critical engine components and airframes.

Technological enhancements such as HVOF, robotic integration, and nanopowder coatings are elevating precision and process efficiency across the board Automated systems increasingly accommodate complex geometries with reduced human error, reflecting Industry 4.0 trends seen in similar equipment sectors.Sustainability imperatives also propel adoption, with thermal spray processes generating less waste compared to traditional methods like plating or welding.These patterns—material dominance, performance-critical applications, automation, and eco‑friendliness—are defining the evolving landscape of the Thermal Spray Equipment Market Market.

Thermal Spray Equipment Market Market Dynamics

The dynamics of the Thermal Spray Equipment Market are fueled by a synergy of customer needs, regulatory forces, and technological shifts. End users across aerospace, automotive, electronics, and power generation seek enhanced wear resistance and protective coatings to enhance asset longevity. This demand has elevated the Market’s profile in corrosion‑prone and high‑temperature environments. Geographically, activity in North America, Europe, and Asia‑Pacific continues to shape investment and technology deployment strategies.

Technological developments like HVOF, plasma spray, and arc techniques improve bond strength, coating density, and efficiency—vital for mission‑critical components where failure isn’t an option. Automation and robotics improve repeatability and operational throughput. Meanwhile, tightening environmental standards and the drive for sustainability are nudging manufacturers toward cleaner, less wasteful thermal spray methods. This confluence of industrial demand, tech evolution, and regulation ensures the Market remains dynamic, competitive, and ripe for innovation.

OPPORTUNITY

"Adoption in Emerging Markets and New Applications"

The Thermal Spray Equipment Market Market presents significant opportunities across Asia-Pacific and niche industries. Asia-Pacific holds nearly 35% of global installations, with China and India leading in new deployments for automotive and infrastructure manufacturing. Electronics and medical implants offer expanding niches, together contributing around 12% of global demand, with cold spray and plasma methods enabling advanced, biocompatible, and miniaturized coatings. Refurbishment applications also present growth potential—thermal spray restores components at up to 40% lower cost than replacement, aligning with circular economy strategies.

DRIVERS

"Expanding Aerospace and Power Generation Demand"

The Thermal Spray Equipment Market Market is experiencing robust growth driven by aerospace and industrial turbine applications. Aerospace alone accounts for nearly 40% of the total demand, as aircraft engines and turbine blades increasingly rely on plasma and HVOF coatings to withstand extreme conditions. Industrial gas turbines contribute around 30%, reflecting their critical role in energy production. Additionally, the automotive sector represents nearly 20%, primarily using electric arc wire systems for brake discs and cylinder liners. Medical and electronics applications cover the remaining 10%, highlighting specialized uses like orthopedic implants and microelectronics coatings.

Market Restraints

"High Capital Investment and Operational Costs"

Despite its advantages, the Thermal Spray Equipment Market Market faces notable restraints. Advanced systems, such as automated plasma spray units, require significant upfront investment, restricting adoption among small and mid-sized enterprises. Operating expenses add pressure, with feedstock costs rising by 8–12% in recent years and energy consumption increasing by 6–9% annually. Maintenance and skilled labor requirements also pose challenges—nearly 25% of service providers report difficulties in retaining trained technicians. These barriers slow adoption in cost-sensitive sectors like automotive and general manufacturing, where ROI timelines are stretched.

Market Challenges

"Rising costs and expenditures"

Rising costs and expenditures related to usage of thermal spray (pharmaceutical-grade) manufacturing equipment and allied consumables are presenting a notable hurdle for manufacturers. For instance, feedstock material prices—like thermal spray powders and wires—have climbed around 8–12 percent in 2024, largely due to increased mineral sourcing and transportation expenses. Moreover, maintenance and energy costs for operating high-temperature Plasma Spray systems or Electric Arc Wire Spray units have surged approximately 6–9 percent year-over-year, driven by escalating electricity tariffs and more stringent preventive maintenance protocols. These cost pressures reverberate through margins, especially for mid-tier OEMs who rely on lower capital intensity. At the same time, compliance with evolving environmental and occupational safety regulations—mandating advanced filtration and dust-collection systems—adds an incremental capital burden of around USD 150,000–USD 300,000 per facility retrofit. Altogether, these elements compound into elevated total cost of ownership, discouraging small-scale adoption and limiting market expansion in cost-sensitive sectors.

Segmentation Analysis

Segmenting the thermal spray equipment market by type (e.g., Flame Spray, Electric Arc Wire Spray, Plasma Spray, Other) and application (Aerospace, Industrial Gas Turbine, Automotive, Other) reveals nuanced growth vectors. For type, Flame Spray systems largely serve corrosion-resistant coatings in general industry, with an estimated installed base of over 10,000 units globally. Plasma Spray dominates in high-performance sectors such as aerospace, accounting for roughly 35 percent of industry revenue in 2024. Electric Arc Wire Spray, offering efficiency and cost-effectiveness for large-area coatings, contributes around 25 percent of equipment shipments. Under “Other,” methods like High Velocity Oxy-Fuel (HVOF) and Cold Spray are growing rapidly—representing approximately 15 percent of segment value thanks to their specialized hardness and cold-work advantages. On the application side, Aerospace remains the largest single‐application segment, capturing nearly 40 percent of equipment revenues, thanks to rigorous wear and thermal barrier coating needs. Industrial Gas Turbine is a strong runner-up, contributing about 30 percent, especially in power generation and marine sectors. Automotive makes up roughly 20 percent, primarily for engine cylinder and brake component refurbishment. The “Other” bucket—including medical, electronics, and oil & gas components—makes up the remaining 10 percent, growing steadily amid customization demand.

By Type

• Flame Spray: Flame Spray systems, one of the earliest thermal spray technologies, remain pivotal for corrosion resistance and rebuild coatings in general industry and infrastructure. There are over 10,000 operational Flame Spray units worldwide as of 2024, particularly concentrated in Asia-Pacific and Europe. The unit cost typically ranges between USD 20,000–USD 50,000 depending on configuration and automation level. Average operating expenses—covering fuel gas and combustion consumables—are estimated at USD 30,000 per year per unit. Notably, Flame Spray coatings help extend component lifespan by 20–40 percent, translating into significant maintenance savings. While simpler and more affordable than other systems, Flame Spray’s relatively lower bond strength and limited substrate versatility do constrain its uptake in ultra-high-performance sectors.

• Electric Arc Wire Spray: Electric Arc Wire Spray has gained prominence due to its efficiency in coating large surfaces. With roughly 5,000–6,000 units shipped globally in 2024, this type accounted for around 25 percent of thermal spray equipment revenues. Capital equipment typically costs between USD 50,000–USD 100,000, while operating costs hover around USD 40,000 annually—driven by electricity and wire consumables. Bond strengths achieved by Electric Arc can be two to three times higher than Flame Spray, making it especially attractive for mid-to-large industrial components. Retrofitting older systems with arc-power units can yield productivity improvements of about 15–20 percent. Despite this, limitations such as narrow material compatibility (primarily metal wires) and line-of-sight constraints still apply.

• Plasma Spray: Plasma Spray remains the premium segment due to its ability to deposit advanced ceramics and alloy coatings. It’s the most lucrative type, generating roughly 35 percent of total equipment market value in 2024, with an estimated 4,000 units in operation globally. Capital investment is substantial: base systems start at USD 120,000 and can exceed USD 500,000 when incorporating robotics and vacuum chambers. Annual operating expenditure, including argon gas, maintenance, and labor, typically ranges between USD 60,000–USD 90,000. The process enables high-density, low-porosity coatings—often exceeding hardness levels of 1,000 HV and bond strengths beyond 40 MPa—making it indispensable in aerospace thermal barrier and industrial turbine applications. However, these capabilities come with price premiums that restrict adoption in cost-sensitive industries.

• Other (e.g., HVOF, Cold Spray): Under “Other,” technologies like High Velocity Oxy-Fuel (HVOF) and Cold Spray are rapidly gaining traction. HVOF, which provides dense, wear-resistant coatings with bond strengths upward of 50 MPa, accounts for approximately 10 percent of equipment revenues in 2024, with unit prices typically between USD 200,000–USD 400,000. Cold Spray—ideal for metallic coating without heat damage—makes up about 5 percent of the segment but is one of the fastest growing, particularly for electronic and medical components. Its equipment is expensive (USD 300,000+) and operational costs vary widely based on powder feed and gas consumption. These newer methods, while expensive, are valued for minimal substrate heating, superior microstructures, and environmental advantages like reduced oxidation, driving their adoption in critical applications despite higher entry costs.

By Application

• Aerospace: The Aerospace sector remains the largest application market for thermal spray equipment, contributing approximately 40 percent of global revenues in 2024. This dominance stems from high-performance coating demands—such as thermal barrier coatings (TBCs) for turbine blades, wear-resistant overlays, and oxidation-inhibiting layers. For example, Plasma Spray TBCs can extend component life by over 50 percent under high-temperature cycles, justifying high equipment and operational costs. Key aerospace OEMs deploy fleets of multi-axis robotic spray cells, with individual system investments surpassing USD 500,000. Maintenance and feedstock costs for this sector are high—with annual budget allocations per line exceeding USD 200,000—because of strict quality standards and certification controls. Consequently, aerospace continues to demand the most technically advanced and capital-intensive thermal spray solutions.

• Industrial Gas Turbine: In the Industrial Gas Turbine (IGT) segment—power generation and marine for instance—thermal spray equipment accounts for roughly 30 percent of market revenues. Providers invest in systems capable of high-reliability coatings, such as MCrAlY bond coats and ceramic topcoats, to boost thermal efficiency and operational uptime. A typical maintenance coat on a gas turbine can save operators up to 5 percent in fuel consumption over a year, equating to USD 100,000–USD 200,000 in annual savings per turbine. Equipment ranges from USD 120,000 (manual) to USD 600,000 (automated vacuum systems), with annual operational costs of USD 70,000–USD 120,000. The demand is increasing: IGT OEMs are estimated to undertake thermal spray maintenance on over 2,000 turbines annually, highlighting the segment’s scale and strategic value.

• Automotive: Automotive comprises about 20 percent of the thermal spray equipment market. Applications include refurbishing engine cylinder liners, coating pistons, and brake disc repair. Electric Arc Wire Spray is popular here due to cost effectiveness and speed: average refurbishment cost savings of up to USD 50 per part compared to replacement, with coating cycle times reduced by around 30 percent. Equipment costs range from USD 50,000 to USD 120,000. In 2024, roughly 3,000 automotive-oriented spray systems were sold globally. With rising demands in electric vehicle (EV) motors and battery thermal management, the automotive segment is poised for further growth, especially for low-heat processes like Cold Spray, which prevents thermal damage to sensitive components.

• Other (Medical, Electronics, Oil & Gas, etc.): The “Other” category—encompassing medical implants, electronics heat-spreaders, oil & gas components, and decorative coatings—accounts for approximately 10 percent of market revenues. Specific use cases include biocompatible coatings in orthopedic and dental implants (via Plasma Spray), which can reduce implant failure rates by up to 15 percent, and electronics applications where fine-tuned aluminum coatings enhance heat dissipation—cutting device temperatures by 10–15 °C. Unit investment ranges widely: desktop micro-spray systems start at around USD 80,000, while ruggedized field units for pipeline repair can cost USD 250,000+. Yearly operations for such niche applications average USD 30,000–USD 50,000. Though smaller in scale, the segment is benefiting from increasing customization and miniaturization trends.

Thermal Spray Equipment Market Regional Outlook

The regional outlook for the thermal spray equipment market displays distinct trends across geographies. North America, especially the U.S., remains a mature, high-value market, driven by aerospace, defense, and power generation sectors. Here, roughly 25–30 percent of global equipment revenues are concentrated, thanks to advanced infrastructure and strong R&D investment. Europe—notably Germany, France, and the UK—captures another 25 percent, buoyed by automotive, industrial machinery, and energy industries; it’s also a hotbed for HVOF and Plasma technology adoption. Asia-Pacific, encompassing China, India, Japan, and South Korea, is the fastest-growing region and now accounts for nearly 35 percent of equipment units and about 30 percent of value. Rapid industrialization, infrastructure development, and automotive manufacturing are key drivers, despite cost sensitivity limiting high-end system installations. Latin America holds around 5–7 percent of the market, with mining and general industrial refurbishment as core segments. Middle East & Africa comprises the remaining 5 percent, supported by oil & gas and power generation projects—where portable spray units for on-site turbine and pipeline maintenance are gaining popularity. Growth forecasts for 2025–2028 indicate Asia-Pacific could outpace others, growing at double the rate of mature regions.

North America

North America stands as a dominant regional hub for thermal spray equipment, particularly in the U.S. and Canada. In 2023, the North American thermal spray equipment market alone exceeded USD 3.3 billion, reflecting the region’s robust reliance on advanced coating technologies . This strength is anchored by aerospace, power generation, and defense sectors, extensively utilizing plasma, HVOF, and electric arc systems for turbine blades, combustion parts, and wear-resistant surfaces. Within the larger thermal spray coatings industry, North America also accounted for over 45.8 percent of total revenues in 2022. Furthermore, in the broader thermal spray coatings revenue share, the U.S. contributed 23.6 percent of global market value in 2023 . These figures underscore the region’s strong installed base, heavy investment in R&D and advanced systems, and high standards for aerospace and energy applications—making North America a mature and value-rich market for thermal spray equipment.

Europe

Europe maintains significant presence in the thermal spray equipment market, with Germany, France, and the UK leading in adoption. The segment benefits from a strong automotive industry and precision manufacturing, where systems like HVOF, plasma, and robotic flame spray are widely used for engine parts, turbine components, and industrial machinery. Europe holds the second-largest regional market share behind North America in thermal spray coatings . The region’s adoption is also supported by major aviation OEMs like Airbus and a network of high-tech coating service providers. In Germany particularly, advanced surface treatment facilities leverage plasma and HVOF for high-wear environments. Regulatory frameworks emphasizing sustainability—such as RoHS and REACH—further drive shifts from chrome plating toward environmentally compliant thermal spray technologies. Collectively, these industry trends and the presence of established coating companies help Europe maintain its critical role in the global thermal spray equipment landscape.

Asia-Pacific

Asia‑Pacific is rapidly ascending as the most dynamic region in the thermal spray equipment space. By 2025, Asia‑Pacific is projected to capture the largest share of the global thermal spray equipment market . Countries like China and India are seeing surge in demand on the back of expanding automotive, aerospace, and energy manufacturing sectors. China stands out with growing adoption in steel plants, gas turbine refurbishment, and industrial roll coatings via HVOF and plasma systems. India, as the fastest-growing market, is increasingly deploying both compact and industrial-grade spray units for manufacturing and refurbishment. The region’s appeal lies in its vast volume opportunities—numerous mid-tier OEMs and service centers are installing affordable flame and arc systems. Moreover, Asia‑Pacific’s market size for thermal spray equipment was already leading globally in 2024–2025. While cost sensitivity remains a factor, the sheer scale of infrastructure and manufacturing growth ensures Asia‑Pacific’s centrality in thermal spray equipment expansion.

Middle East & Africa

Middle East & Africa (ME&A) comprises a smaller, yet strategically important, segment within the thermal spray equipment market. The region’s primary demand stems from oil & gas, petrochemical, and power generation projects—sectors that require on-site refurbishment and thermal barrier treatments of turbine blades, pipeline components, and other critical assets. The use of portable electric arc and plasma spray systems is increasingly prevalent for maintenance in remote facilities. While ME&A together contributes around 5 percent to the aerospace thermal spray equipment revenue base , the actual equipment deployment spans various energy-centric applications. Countries like UAE, Saudi Arabia, and South Africa are investing in modernization of power plants and industrial infrastructure, creating a niche but steady demand for thermal spray equipment. The region's reliance on robust coating systems that resist corrosion and high temperatures makes it a key area for targeted sales and service strategies, even if overall volumes remain modest relative to North America or Asia-Pacific.

List of Key Thermal Spray Equipment Market Companies Profiled:

Investment Analysis and Opportunities

Investment opportunities in the thermal spray equipment market are increasingly attractive across both mature and emerging economies. In North America and Europe, capital expenditures are flowing into robotic plasma spray systems and automated HVOF facilities, with an estimated 28 percent of new investment directed toward aerospace and turbine sectors. The automotive industry is contributing nearly 20 percent of global equipment demand, with investments largely focused on Electric Arc Wire Spray systems for brake discs, piston coatings, and cylinder liners. Asia-Pacific represents the most aggressive investment landscape, with over 35 percent of new equipment installations occurring in China, India, Japan, and South Korea, reflecting the region’s scale of industrialization. Additionally, the medical and electronics fields together account for around 12 percent of fresh capital inflows, primarily into plasma and cold spray systems for implants and microelectronics. Opportunities are evident in sustainability initiatives: 15 percent of global investments in 2024 were directed toward equipment that reduces emissions, energy consumption, or toxic byproducts. Strategic partnerships between OEMs and coating service providers are also emerging, with co-investment models allowing smaller operators to access advanced spray equipment without bearing full upfront costs. Altogether, the market presents a fertile ground for diversified investment, with high-return opportunities in both established industries and niche applications.

NEW PRODUCTS Development

New product development in thermal spray equipment is being driven by the demand for higher coating efficiency, lower operational costs, and compliance with stricter environmental standards. Recent introductions have focused on compact, automated plasma spray units capable of achieving coating deposition rates up to 15 percent higher than conventional systems, allowing faster throughput. HVOF systems launched in 2023–2024 feature fuel efficiency improvements of around 12 percent, reducing operating expenditure while maintaining dense, wear-resistant coatings. In the cold spray category, manufacturers have unveiled portable systems that support deposition speeds exceeding 800 m/s, enabling use in aerospace and defense for lightweight alloy coatings. Product designs are also trending toward integration with Industry 4.0 technologies—about 18 percent of new systems now include IoT-enabled monitoring tools for real-time process control and predictive maintenance. Safety enhancements have also become standard: newer flame spray models incorporate dust and fume capture efficiency of over 95 percent, exceeding previous regulatory compliance levels. Furthermore, modular designs are gaining traction, enabling users to adapt one system for multiple spraying methods, improving flexibility and ROI. Collectively, these new developments are ensuring that thermal spray equipment remains competitive and aligned with evolving industrial needs across aerospace, automotive, power generation, and healthcare.

Recent Developments by Manufacturers

1. Oerlikon launched a next-generation plasma spray system in 2023, improving deposition density by 10 percent for aerospace applications.

2. Praxair Surface Technologies introduced a modular HVOF unit in 2024, achieving 12 percent lower fuel consumption while maintaining hardness standards.

3. Metallisation Ltd. rolled out a new arc spray robot cell in 2023, capable of coating 15 percent larger surface areas per cycle.

4. Sprimag unveiled an automated coating line in 2024, integrating robotic handling to cut processing times by 20 percent in automotive production.

5. SciTeeX released an advanced cold spray portable unit in 2024, reducing on-site turbine repair downtime by 30 percent for power generation clients.

REPORT COVERAGE of Thermal Spray Equipment Market

The report on the thermal spray equipment market provides comprehensive coverage of all critical dimensions, including market segmentation, technology adoption, application analysis, competitive landscape, and regional distribution. By type, the report covers Flame Spray, Electric Arc Wire Spray, Plasma Spray, and Other methods such as HVOF and Cold Spray, with detailed share distribution and performance insights. By application, the scope spans Aerospace, Industrial Gas Turbine, Automotive, and Other end-uses like medical and electronics, quantifying their respective contribution to global demand. The report also highlights regional outlooks, showing Asia-Pacific accounting for 35 percent of unit installations, North America at 30 percent, Europe at 25 percent, and Middle East & Africa at 10 percent, with specific emphasis on country-level performance. Competitive analysis includes profiling of leading manufacturers such as Oerlikon, Praxair Surface Technologies, Metallisation, and SciTeeX, supported by facts on their technology innovations, partnerships, and market shares. In addition, the coverage extends to investment trends, sustainability practices, and regulatory influences shaping adoption across industries. The report ensures clarity by combining quantitative data with qualitative insights, helping stakeholders identify growth opportunities, evaluate risks, and plan long-term strategies. Overall, the report delivers a concise yet detailed overview of market dynamics, ensuring readers can make data-driven decisions.