Thermal Spray Equipment Market to Surpass USD 23.8 Billion by 2035 — Growth Surges Across APAC, Europe & USA

The global Thermal Spray Equipment Market is on a strong upward trajectory, projected to expand from USD 13.9 billion in 2025 to USD 23.8 billion by 2035, registering a CAGR of 5.5%. This growth reflects rising global demand for high-performance coatings that enhance durability, corrosion protection, and heat resistance in aerospace, automotive, and energy applications.

During 2025–2030, the market will climb to USD 18.2 billion, adding USD 4.3 billion in incremental value, largely powered by aerospace maintenance and advanced engine components. From 2030–2035, an even stronger USD 5.6 billion contribution is expected, supported by automation, robotics, and high-velocity oxygen fuel (HVOF) technologies.

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Innovation at the Core of Market Expansion

As industries shift toward sustainability and precision engineering, thermal spray technology is becoming indispensable for performance-critical components. Manufacturers are adopting robotic spray systems, digital monitoring tools, and energy-efficient equipment to ensure accuracy and consistency while cutting operational costs.

Oerlikon Metco, Praxair Surface Technologies, Saint-Gobain, Sulzer Ltd., and Flame Spray Technologies BV are leading this transformation. They’re investing in IoT-enabled automation and nanostructured coating powders, allowing operators to achieve higher coating uniformity with less waste—an increasingly important factor as industries embrace cleaner production models.

Emerging firms, particularly in Asia and Eastern Europe, are also carving out a niche with cost-effective modular spray systems. These systems provide flexibility for small- and medium-sized workshops entering high-performance coating applications.

Regional Highlights: APAC Takes the Lead

Asia-Pacific (APAC) is set to dominate global growth with China and India leading at 7.4% and 6.9% CAGR, respectively. China’s rise stems from its booming aerospace, power generation, and automotive industries, alongside robust investment in renewable energy and wind turbine coatings. Domestic suppliers are enhancing local availability of advanced equipment, while foreign entrants strengthen partnerships to meet industrial automation demand.

In India, infrastructure growth and manufacturing expansion drive adoption of thermal spray solutions for heavy-duty components in railways, turbines, and automotive sectors. Collaboration between domestic and global players is fostering a wave of innovation aimed at improving coating reliability and affordability.

Meanwhile, Germany leads Europe’s high-precision segment, with 6.3% CAGR, emphasizing eco-friendly coatings, plasma systems, and HVOF technologies for automotive and medical device applications. The United States remains a powerhouse for defense and aerospace coatings, where digitalized and automated systems enhance process reliability and component life cycles.

Automation and Sustainability Define the Future

Automation is poised to reshape the market—automatic thermal spray systems already account for over 50% of revenue share. These systems provide repeatability, improved coating uniformity, and reduced material waste. As manufacturers pursue smart factory initiatives, the integration of robotic spray cells, AI-based process control, and real-time diagnostics will define the next generation of thermal spray equipment.

Sustainability also plays a critical role. The market is shifting away from hard chrome plating toward thermal spray coatings, which offer environmentally safer and longer-lasting alternatives. Reduced downtime, enhanced wear resistance, and energy-efficient operation make these systems ideal for the circular economy of industrial production.

Competitive Landscape: Innovation Drives Differentiation

The market’s competitive edge lies in technological innovation and service-based models. Companies are increasingly offering turnkey coating solutions, leasing programs, and predictive maintenance services to meet the evolving needs of repair and refurbishment sectors. By blending hardware excellence with data-driven insights, leading players are setting new standards for coating precision and lifecycle cost optimization.

Collaborations with feedstock material suppliers are also shaping the market, enabling the development of application-specific powders and wires that deliver better adhesion and surface hardness—critical for the aerospace and energy industries.

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Outlook: A Decade of Transformation Ahead

From engine refurbishments to turbine blade coatings, thermal spray equipment is redefining how industries approach component longevity and efficiency. The decade ahead promises digitalized, automated, and eco-efficient growth as the technology cements its role at the core of advanced manufacturing.

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