Thermal Spray Equipment Market Size - By Equipment Type, By Surface Type, By Operation, By End-use Industry, By Distribution Channel & Forecast, 2024 - 2032

Thermal Spray Equipment Market Size

The global thermal spray equipment market was valued at USD 12.5 billion in 2023 and is estimated to grow at a CAGR of 5.5% during 2024 to 2032. Thermal spray equipment is widely used across various industries, including aerospace, automotive, electronics, and energy.
 

The aerospace sector, for instance, requires high-performance coatings to enhance the durability of components exposed to extreme conditions. Similarly, the automotive industry uses thermal spray coatings for wear resistance and corrosion protection. As these industries continue to expand, driven by increasing production rates and the need for advanced materials, the demand for thermal spray equipment is likely to grow. New applications in emerging sectors, such as medical devices and renewable energy, further augment market potential. The increasing focus on surface protection to enhance the lifespan of components is a significant demand driver. Thermal spray coatings provide effective solutions for protecting parts from wear, corrosion, and oxidation.
 

As industries prioritize maintenance and longevity to reduce operational costs, the adoption of thermal spray technology is expected to increase. This trend is particularly evident in sectors like oil and gas, where equipment is subjected to harsh environments, necessitating robust protective coatings.
 

One of the most significant barriers to entry for businesses looking to adopt thermal spray technology is the high initial investment required for equipment and setup. Thermal spray systems can be costly, and smaller companies may struggle to secure the necessary capital. The technical complexity of thermal spray processes presents another challenge. Effective operation and maintenance of thermal spray equipment require specialized knowledge and skills. There is often a shortage of trained personnel who can operate these systems efficiently, leading to potential downtime and increased operational costs.
 

Thermal Spray Equipment Market Trends

As industries strive for greater efficiency and precision, there is a notable shift towards automated and robotic thermal spray systems. These technologies enhance consistency in coating applications and reduce human error, leading to improved product quality and reduced operational costs. Manufacturers are increasingly investing in automated solutions to streamline production processes and meet the rising demand for high-quality coatings in sectors like aerospace, automotive, and electronics.
 

There is a growing demand for advanced coating technologies, such as High-Velocity Oxygen Fuel (HVOF) and Plasma Spray, which offer superior performance characteristics. These technologies are increasingly preferred for their ability to create dense, durable coatings that can withstand extreme conditions. As industries seek to improve component longevity and performance, the adoption of these advanced coating methods is expected to rise.
 

Thermal Spray Equipment Market Analysis

The spray system was worth over USD 3.2 billion in 2023 and is expected to reach USD 5.6 billion by 2032. Continuous improvements in spray technologies, such as High-Velocity Oxygen Fuel (HVOF) and Plasma Spray, enhance the quality and efficiency of coatings. Industries require tailored coating solutions for specific applications, leading to increased demand for versatile spray systems that can accommodate various materials and processes. Expanding sectors like aerospace, automotive, and energy are driving the need for high-performance coatings, boosting the demand for advanced spray systems.
 

Based on surface type, the metals segment accounted for a market share of around 41% in 2023 and is projected to grow by 2032. The demand for thermal spray coatings using metals is primarily driven by their excellent mechanical properties, wear resistance, and thermal stability. Industries such as aerospace, automotive, and energy increasingly require metal coatings to enhance component durability and performance. The ability to apply coatings like chromium, nickel, and tungsten carbide significantly extends the life of parts subjected to harsh environments, such as turbines and engine components.
 

Moreover, the trend towards refurbishing and repairing existing machinery rather than replacing it fuels the need for metal thermal spray solutions that can restore original specifications.
 

North America thermal spray equipment market size surpassed USD 3.3 billion in 2023 and is expected to reach USD 5.4 billion by 2032. The U.S. and Canada have strong aerospace industries that utilize thermal spray coatings for lightweight, high-performance components. The focus on innovation and improving fuel efficiency drives demand.
 

The market in U.S. is set to grow at a CAGR of over 5.6% through 2032. Increasing production and repair activities in the automotive sector necessitate advanced thermal spray technologies for enhancing wear resistance and thermal management.
 

The German thermal spray equipment market maintained a considerable position in Europe. Increased investments in wind and solar energy applications boost the demand for thermal spray coatings that enhance the durability of components used in harsh environments.
 

China is supposed to grow at the highest rate of 6.6% in the region. As the aerospace and automotive industries expand in the region, the need for advanced coating technologies to enhance component performance becomes more critical.
 

Thermal Spray Equipment Market Share

The thermal spray equipment industry seems to be consolidated in nature due to presence of local and global players across the globe. In 2023, the market players such Linde, Aimtek, Curtiss-Wright, Saint Gobain, A&A Thermal Spray Coatings, Ador Fontech, Alloy Metal Surface Technologies and Bodycote collectively held around 10%-20% market share. 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 broader customer base, and strengthen their market position.
 

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
   

Thermal Spray Equipment Industry News

• In June 2024, Oerlikon inaugurated an Advanced Coating Technology Centre, bolstering its expertise in thermal spray technology, particularly for the aerospace and gas turbine sectors. This move underscores Oerlikon's dedication to pioneering advancements in thermal spray technologies and delivering top-tier coating solutions for vital aerospace and gas turbine applications.
   

This thermal spray equipment market research report includes in-depth coverage of the industry with estimates & forecast in terms of revenue (USD Billion)(Thousand Units) from 2021 to 2032, for the following segments:

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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
  • UK
  • Germany
  • France
  • Italy
  • Spain
  • Russia
• Asia Pacific
  • China
  • India
  • Japan
  • South Korea
  • Australia 
• Latin America
  • Brazil
  • Mexico
• MEA
  • UAE
  • Saudi Arabia
  • South Africa