Thermal Spray Coating Equipment and Services Market Report Scope & Overview:

The Thermal Spray Coating Equipment and Services Market Size was valued at USD 12.77 Billion in 2023 and is expected to reach USD 18.88 Billion by 2032 and grow at a CAGR of 4.50% over the forecast period 2024-2032.

The Thermal Spray Coating Equipment and Services Market is growing strongly as a result of growing demand for surface protection, wear resistance, and thermal barriers in industries such as aerospace, automotive, energy, and healthcare. The market includes a broad array of technologies, ranging from plasma spray, high-velocity oxy-fuel (HVOF), and flame spray systems, backed by extensive service solutions. Increased emphasis on increasing component life, lowering the cost of maintenance, and enhancing operational efficiency is fueling demand across the world.

The U.S. Thermal Spray Coating Equipment and Services Market  was valued at USD 2.95 Billion in 2023 and is projected to grow to USD 4.12 Billion at a CAGR of 3.87% during 2024-2032.The U.S. Thermal Spray Coating Equipment and Services market is growing robustly with growth in aerospace, automotive, and energy industries. Growth in demand for hard, corrosion-resistant, and heat-resistant coatings is fueling uptake of technologies such as plasma spray and HVOF. Availability of large-scale manufacturers, strong R&D infrastructure, and higher defense and aviation investments are also boosting the market. U.S. firms also emphasize automation and precision in coating application to achieve high quality standards.

Thermal Spray Coating Equipment and Services Market Dynamics

Key Drivers:

• Increased Need for Environmentally Friendly Products in Different Sectors Drives the Thermal Spray Coating Equipment and Services Growth.

Aerospace, automotive, and power generation sectors are increasingly adopting eco-friendly options to address regulatory requirements and sustainability agendas. Thermal spray coatings, which extend the life cycle of components and help minimize the need for frequent replacement, are gaining popularity as an environmentally friendly alternative to conventional options. The reduced material waste and minimized use of harmful chemicals are in alignment with global emission reduction strategies. This increasing trend for more environmentally friendly materials and energy-efficient processes for coating is fueling the need for more advanced thermal spray equipment and service solutions throughout the United States and internationally.

Restrain

• Sizable Initial Capital Investment in Equipment Hinders the Acceptance of Thermal Spray Coating Technologies Throughout Small to Mid-Sized Businesses.

In spite of the long-term cost-effectiveness and longevity provided by thermal spray coatings, the up-front capital for equipment installation and trained labor is still a major hurdle. Small and medium-sized businesses do not have the financial leeway to invest in sophisticated spray systems like HVOF or plasma spray. Moreover, the maintenance, training, and integration costs into current production lines make it difficult to adopt. This economic limitation retards market penetration in cost-conscious industries and geographies, especially where technological upgrading is still underway.

Opportunities

• Increasing Use of Thermal Spray Coatings in Medical Implants and Biomedical Devices Generates New Market Revenues.

The health sector is a potential market for thermal spray coatings because of the increasing application of implants and surgical tools with a need for wear resistance and biocompatibility. Titanium and hydroxyapatite coatings using thermal spray methods enhance osseointegration and longevity of orthopedic implants. As the population ages in the United States and dental and joint replacement needs increase, so does demand for trustworthy coating technology. Such a trend represents high growth prospects for equipment vendors and service firms capable of servicing strict medical quality standards and offering innovations in this specialized application category.

Challenges

• Skilled Technicians Shortage and Process Standardization Confront the Scalability and Consistency of Thermal Spray Coating Services.

Notwithstanding developments in technology, thermal spray manufacturing has the inability to get professionals qualified to manage and service high-performance coating machines. Complexity associated with processes such as plasma and HVOF spraying necessitates expert know-how and attention to detail. Additionally, differences in standards and absence of standard training guidelines result in non-uniform quality of coatings, impacting customer satisfaction and long-term trust. Such a talent and standardization gap prevents scalability, especially for service providers who are looking to expand operations or foray into highly regulated industries like aerospace or biomedical. Closing the talent and standardization gap is essential to be able to harness the complete potential of the market.

Thermal Spray Coating Equipment and Services Market Segments Outlook

By Product

The Services segment dominated the Thermal Spray Coating Equipment and Services Market in 2023 with a commanding revenue share of 50.06% due to increasing demand for specialized surface treatment services in aerospace, automotive, and energy sectors. Oerlikon Metco and Bodycote have been expanding service portfolios and providing on-site coating, inspection, and repair solutions. For instance, Oerlikon introduced enhanced service centers in Europe and the U.S. in 2023 to raise turnaround, as well as coating accuracy, times. Moving towards improved turnkey contracts to help cut down complexity and increase coating consistency further enhances the stature of the service-based model in the market.

The Equipment segment is expected to expand at the highest CAGR of 5.56% during the forecast period, driven by improvements in automation, precision control, and process scalability. The players such as Praxair Surface Technologies and Saint-Gobain have launched next-gen thermal spray systems with real-time monitoring and energy-saving features. For example, Praxair's newest plasma spray equipment, released in late 2023, has IoT capabilities for predictive maintenance and performance monitoring. The increasing demand for in-house coating solutions and customization in industries such as defense and healthcare is driving the demand for advanced, high-performance thermal spray equipment worldwide.

By Process

The Combustion process segment contributed the highest percentage in the Thermal Spray Coating Equipment and Services Market in 2023 with 58.79% of the total revenue. This dominance can be attributed to its cost-effectiveness, ease of operation, and widespread application across industries like automotive, aerospace, and energy. Industries have seen the introduction of sophisticated flame spray systems and HVOF (High Velocity Oxy-Fuel) solutions by companies like Oerlikon Metco and Praxair Surface Technologies to improve coating performance and efficiency. For instance, Oerlikon's SmartCoatPro launch has automated combustion-based spraying with the infusion of real-time control, which further consolidated the segment leadership in industrial usage.

The Electrical Energy segment is likely to exhibit the highest growth rate in the Thermal Spray Coating Equipment and Services Market during the forecasted period with a CAGR of 5.30%. This expansion is fueled by mounting demand for high-quality, accurate coatings in delicate applications like biomedical devices, semiconductors, and electronics. Electrical energy-based plasma spray technology is becoming more popular due to its capability to provide dense and even coatings. Saint-Gobain and Progressive Surface are examples of firms that have launched next-generation plasma spray systems designed specifically for use in medical implants and turbine parts. This development facilitates wider use of electrically powered coating processes in high-performance industries.

By End-User

The Aerospace industry led the Thermal Spray Coating Equipment and Services Market in 2023 with 35.61% of overall revenue, led by growing demand for lightweight, wear-resistant, and heat-resistant parts. Large OEMs like Boeing and Airbus, as well as suppliers including Rolls-Royce and GE Aerospace, have incorporated advanced thermal spray processes for improving turbine blades, engine components, and landing gear resilience. Interestingly, in 2023, Oerlikon introduced high-performance HVOF systems customized for aerospace applications, and Praxair Surface Technologies expanded its coatings plant in Indiana. These advances underscore the industry's dependence on thermal spray technology to enhance efficiency and increase the lifespan of aircraft components.

The healthcare segment is expected to register the highest CAGR of 6.26% during the forecast period due to increasing demand for biocompatible and wear-resistant coatings for medical implants and surgical instruments. Thermal spray coatings such as titanium and hydroxyapatite are becoming popular in orthopedic and dental implants to enhance osseointegration and decrease the rate of rejections. Bodycote opened new thermal spray facilities in North America in 2023 to address escalating demand for medical devices, as Medtronic and Zimmer Biomet hastened to develop joint implants with coating.

Thermal Spray Coating Equipment and Services Market Regional Analysis

North America was the biggest revenue contributor with a share of 33.16% in 2023 due to high demand in aerospace, defense, and automotive industries. Continuous innovation is facilitated by the presence of industry leaders like Oerlikon Metco, Praxair Surface Technologies, and Curtiss-Wright Corporation. In 2023, Oerlikon Metco increased its thermal spray plant capacity in Connecticut to address increasing aerospace demands, and Praxair launched new HVOF coating systems for turbine parts. These advances complement the region's emphasis on wear-resistant, corrosion-resistant, and high-performance coatings. The well-established industrial base and sophisticated R&D infrastructure further consolidate North America's position in thermal spray coating equipment and services.

Asia Pacific is anticipated to register the maximum CAGR of 5.82% during the forecast period, driven by rapid industrialization, infrastructure growth, and aerospace advancement in countries such as China, India, and Japan. In 2023, Tocalo Co., Ltd. broadened its thermal spray service centers in Southeast Asia, while Mitsui Engineering & Shipbuilding launched new flame spray systems for shipbuilding applications. Growing investments in automotive production and renewable energy further fuel the development of the region. With heightened demand for protective coatings and regional production capacity, Asia Pacific is emerging as a strategic hub for thermal spray equipment and service companies looking to expand globally.

Thermal Spray Coating Equipment and Services Market Key Players are:

• Linde AMT – (LINSPRAY HP 750, LINSPRAY Connect Software)

• Ador Fontech Limited – (JetSpray Thermal Spray System, Plasma Transferred Arc (PTA) Equipment)

• Bodycote – (Thermal Spray Coating Services, HVOF Surface Coatings)

• Curtiss-Wright Corporation – (C-W Thermal Spray Systems, BlackGold Coating Services)

• OC Oerlikon Management AG – (MetcoJet HVOF System, SmartCoat Thermal Spray Software)

• Kennametal Inc. – (JetKote Thermal Spray Equipment, Stellite Wear-Resistant Coatings)

• Saint Gobain – (ProPlasma HP Gun, Flame Spray Powder Materials)

• The Lincoln Electric Company – (Thermal Arc Spray Equipment, UltraCore Coating Wires)

• A&A Thermal Spray Coatings – (HVOF Coating Services, Plasma Spray Coatings)

• Aimtek – (Thermal Spray Powders, Thermal Spray Torch Kits)

• Alloy Metal Surface Technologies – (Ceramic Coating Services, Wire Flame Spray Systems)

• Wall Colmonoy – (Colmonoy Powder Alloys, Fusewelder Spray & Fuse Equipment)

• Hannecard Roller Coatings, Inc. – (HanneSpray Coatings, Industrial Roller Thermal Spray Services)

• Brycoat Inc. – (Vacuum Plasma Spray Coatings, Ceramic Thermal Spray Coatings)

• Höganäs AB – (Amperit Thermal Spray Powders, Plasma Transferred Arc Solutions)

• General Magnaplate Corporation – (Plasmadize Coatings, Nedox Thermal Spray Surface Treatments)

• Flame Spray Technologies BV – (Arc Spray System FST-ArcJet, HVOF System FST-MultiCoat)

• Others – (Customized HVOF Equipment, On-site Coating Services)

Recent Develoepment

• October 2023 – Linde AMT introduced LINSPRAY Connect, a cloud-based software that enables real-time control, predictive maintenance, and process analytics for thermal spray equipment, improving precision and reducing downtime.