Thermal Spray Equipment Market Size, Share, Trends, Demand, Growth Forecast, Segmentation and Revenue Outlook

The thermal spray equipment market is gaining significant traction worldwide, driven by the increasing demand for durable coatings across a range of industrial applications. Thermal spraying, a process that involves coating surfaces with melted or heated materials, is widely utilized in industries such as aerospace, automotive, healthcare, energy, and electronics. This method enhances surface properties, including corrosion resistance, thermal insulation, and wear resistance, making it a vital part of manufacturing and maintenance operations.

Market Overview

As of 2025, the global thermal spray equipment market is experiencing steady growth and is expected to continue on this trajectory over the next decade. The market includes various equipment types such as flame spray, electric arc spray, plasma spray, and high-velocity oxy-fuel (HVOF) systems. These technologies are selected based on their compatibility with coating materials and specific application requirements.

"The Thermal Spray Equipment Market is projected to grow from USD 5.86 billion in 2024 to USD 10.5 billion by 2035, at a compound annual growth rate (CAGR) of approximately 5.44% during the forecast period from 2025 to 2035.

Key Market Drivers

1. Rising Demand in Aerospace and Automotive Industries:
   Thermal spray coatings are critical in aerospace and automotive manufacturing due to their ability to withstand extreme temperatures and mechanical stress. In jet engines and automotive parts, thermal spray coatings protect components from corrosion and high heat, enhancing lifespan and performance. The growing production of aircraft and automobiles globally is fueling demand for thermal spray equipment.
2. Growth in Renewable Energy and Power Generation:
   In energy and power generation, thermal spray is used to coat gas turbines, boilers, and nuclear reactors to protect them from harsh operational environments. The shift toward renewable energy, such as wind and solar, also requires robust equipment coatings, driving further demand for thermal spray solutions.
3. Increasing Use in Medical Devices and Implants:
   The healthcare industry is leveraging thermal spray coatings in orthopedic implants and surgical instruments. These coatings enhance biocompatibility and durability, which are essential in implants such as hip and knee replacements. As healthcare demand increases, especially in aging populations, this sector becomes a growing contributor to the thermal spray equipment market.
4. Advancements in Coating Materials and Processes:
   Ongoing R&D is leading to innovations in spray materials and deposition techniques. These advancements are improving efficiency, coating quality, and material compatibility, which in turn are increasing the adoption of thermal spray technologies across new sectors.

Market Segmentation

The thermal spray equipment market can be segmented based on:

• Process Type: Flame spray, plasma spray, HVOF, electric arc spray, cold spray.
• Application: Aerospace, automotive, industrial gas turbines, medical, oil & gas, electronics.
• Region: North America, Europe, Asia-Pacific, Latin America, Middle East & Africa.

North America and Europe currently dominate the market, primarily due to well-established aerospace and defense sectors and early adoption of advanced coating technologies. Asia-Pacific, however, is expected to register the highest growth due to rapid industrialization, particularly in China, India, and Southeast Asia.