• Market Size & Growth: The global thermal spray equipment market was valued at approximately USD 12.5 billion in 2023 and is projected to reach USD 23.8 billion by 2035, growing at a CAGR of 5.5% from 2024 to 2035. This growth is driven by increasing demand for durable and high-performance coatings across industries such as aerospace, automotive, energy, and electronics.

• Key Equipment Types: The market is segmented into various equipment types, including spray systems, dust collection equipment, and spray guns and nozzles. Spray systems accounted for over USD 3.2 billion in 2023 and are expected to reach USD 5.6 billion by 2032, driven by advancements in coating technologies like High-Velocity Oxygen Fuel (HVOF) and Plasma Spray.

• Surface Type Segmentation: Metals dominated the market with a share of approximately 41% in 2023, owing to their excellent mechanical properties, wear resistance, and thermal stability. The demand for metal coatings is primarily driven by industries such as aerospace, automotive, and energy, which require components to withstand harsh operating conditions.

• Regional Insights: North America held the largest revenue share of 38.5% in 2023, driven by strong aerospace industries in the U.S. and Canada. The region's focus on innovation and improving fuel efficiency in aerospace applications contributes to the demand for advanced thermal spray coatings. Asia-Pacific is expected to witness significant growth, particularly in China, due to expanding aerospace and automotive industries.

• Technological Advancements: The adoption of automated and robotic thermal spray systems is increasing, enhancing consistency in coating applications and reducing human error. Innovations in coating technologies, such as HVOF and Plasma Spray, offer superior performance characteristics, leading to their growing preference for applications requiring dense and durable coatings.

• End-Use Industry Applications: Thermal spray equipment is widely used in various industries, including aerospace, automotive, electronics, and energy. In aerospace, thermal spray coatings are applied to turbine blades and other components to enhance durability and performance. In the automotive industry, coatings are used for wear resistance and thermal management in engine components.

• In June 2024, Oerlikon inaugurated its Advanced Coating Technology Centre, enhancing its capabilities in thermal spray technology for the aerospace and gas turbine sectors. This facility aims to deliver top-tier coating solutions for critical applications, reinforcing Oerlikon's commitment to innovation in surface engineering.

• In April 2024, Höganäs AB received the "Partner of the Year" award from Mitsubishi Heavy Industries for its exceptional supply of thermal spray powders. This recognition highlights Höganäs' dedication to quality and its pivotal role in supporting advanced manufacturing processes.

In this report, the Thermal Spray Equipment Market has been segmented by Equipment, Surface, Operation, End-User, Distribution Channel and Geography.

Thermal Spray Equipment Market, Segmentation by Equipment

The Equipment axis distinguishes capital systems and peripherals that enable coating deposition, production uptime, and process control across diverse industries. Buyers prioritize process capability, throughput, cost per part, and HSE compliance as critical drivers, while capex intensity, operator skill gaps, and maintenance complexity remain key challenges. Vendors increasingly pursue partnerships with materials suppliers and robotic integrators, embedding automation, closed-loop monitoring, and digital twins to support expansion into high-spec applications and deliver a resilient future outlook.

Spray Systems

Spray Systems represent the core of thermal spray operations, defining torch technology, heat source, and particle dynamics to achieve targeted bond strength, microstructure, and coating performance. Selection is shaped by substrate sensitivity, deposition rate, and coating materials, with customers balancing capex vs. OPEX trade-offs. Integrated controls, real-time diagnostics, and standardized recipes enable repeatability across cells, supporting quality assurance and multi-plant scaling.

• Plasma

  Plasma spray systems provide high enthalpy for dense, low-oxide coatings on metals, ceramics, and advanced composites. They are favored where thermal efficiency, microstructural control, and coating integrity are paramount, including aerospace hot-section parts and biomedical implants. Ongoing technological advancements include improved torch designs, better powder injection, and sensorized control loops that stabilize arcs and enhance process reliability.

• Twin Arc

  Twin Arc (electric arc) systems deliver high deposition rates with cost-effective wire feedstocks, making them attractive for large-area rebuilds, corrosion protection, and repair. Their comparatively lower heat input benefits heat-sensitive substrates and field applications. Suppliers focus on operator safety, spray plume control, and improved arc stability to reduce porosity while maintaining economical total cost of ownership.

• Flame Spray

  Flame Spray uses combustion heat to apply metal or polymer coatings where simplicity, portability, and cost are decisive. It supports maintenance, repair, and overhaul scenarios, enabling flexible on-site work. Modern systems emphasize fuel efficiency, nozzle durability, and safer gas handling, aligning with tightening environmental and workplace standards.

• HVOF

  HVOF (High Velocity Oxy-Fuel) produces high-density coatings with exceptional adhesion and wear resistance, widely adopted for tungsten carbide and anti-corrosion overlays in aerospace, energy, and industrial components. The technology’s hallmark is high particle velocity, yielding low oxide content and superior surface properties. Suppliers invest in combustor optimization, fuel management, and in-situ diagnostics to enhance repeatability and lifecycle value.

• Powder Flame Spray

  Powder Flame Spray extends flame spraying for powder feed, allowing diverse material chemistries and coating architectures. It balances equipment simplicity with improved deposition flexibility, making it a choice for medium-spec applications. Growth is supported by powder feeder advances, nozzle design improvements, and better process recipes that broaden addressable use cases.

• Others

  Others capture niche or emerging spray modalities and hybridized cells that tailor thermal profiles and particle trajectories to unique performance targets. This includes specialized torches, custom robots, and integrated pre/post-treatment steps. Innovation and partnerships with OEMs enable pilot deployments that, over time, can scale into standardized offerings.

Booths

Booths provide controlled environments for overspray capture, acoustic attenuation, and emissions control, ensuring regulatory compliance and workplace safety. They contribute to consistent coating quality by stabilizing airflow and temperature, and by integrating interlocks for operator protection. Vendors differentiate with modular construction, NFPA-aligned designs, and compatibility with robotic manipulators and part-positioning systems.

Dust Collection Systems

Dust Collection Systems protect equipment, operators, and adjacent processes by capturing particulate and fume generated during spraying and finishing. Effective filtration reduces rework and enhances yield, while enabling compliance with air quality standards. Buyers favor high-efficiency filters, smart differential-pressure monitoring, and simplified maintenance for sustained OEE.

Chillers

Chillers stabilize process temperatures for torches, feeders, and ancillary components, directly influencing arc stability and coating consistency. Better heat management reduces downtime and extends component life. Suppliers emphasize energy efficiency, closed-loop controls, and compact footprints to fit constrained cells while meeting ESG objectives.

Spray Guns & Nozzles

Spr

Industrial Hose Assemblies Market

By Material Type;

Rubber, PVC, Polyurethane, Silicone and Others

By Application;

Oil & Gas, Chemicals, Food & Beverages, Agriculture, Construction and Others

By Pressure Rating;

Low Pressure, Medium Pressure and High Pressure

By End-User;

Manufacturing, Automotive, Pharmaceuticals, Mining and Others

By Geography;

North America, Europe, Asia Pacific, Middle East & Africa and Latin America

ay Guns & Nozzles are wear-critical parts that define plume shape, particle residence time, and substrate impact. Advanced materials and precision machining improve durability and consistency, lowering cost per hour. The segment advances via nozzle aerodynamics, better cooling, and quick-change designs that shorten setup and maintenance intervals.

Feeder Systems

Feeder Systems govern powder or wire delivery, impacting deposition rate, coating homogeneity, and repeatability. Modern feeders feature closed-loop mass flow, traceable recipes, and integrated MES connectivity. This enables data-driven quality control, supports validation in regulated industries, and underpins multi-site standardization.

Gas Systems

Gas Systems ensure safe, precise control of fuel and process gases, a prerequisite for combustion stability and consistent energy delivery. Solutions include certified manifolds, flow controllers, and interlocks that align with stringent safety frameworks. Suppliers highlight leak detection, ergonomic panels, and digital logging to meet compliance and audit needs.

Others

Others include tooling, manipulators, masking, and pre/post-processing equipment that complete the cell. These assets drive throughput and first-pass yield by improving part presentation, surface preparation, and finishing. Growth is linked to integrated workcells where vendors deliver turnkey process capability and lifecycle support.

Thermal Spray Equipment Market, Segmentation by Surface

The Surface axis reflects substrate classes—Metals, Ceramics, Polymers, and Composites—with differing thermal tolerances, expansion coefficients, and bond mechanisms. Purchasing decisions hinge on coating-substrate compatibility, desired functional properties (wear, corrosion, thermal barrier), and repair vs. OEM economics. Vendors that offer validated process windows and robust application engineering help reduce qualification cycles and unlock broader adoption.

Metals

Metals dominate heavy-duty applications where structural integrity and wear performance are critical, such as shafts, rolls, and turbine components. Spray parameters focus on minimizing dilution and residual stress while maximizing adhesion. Growth is driven by lifecycle extension strategies and the replacement of hard chrome with HVOF carbides in sustainability-focused upgrades.

Ceramics

Ceramics enable high-temperature stability and thermal insulation, vital for hot-section aerospace and energy components. Plasma spray is often preferred to achieve dense, controlled microstructures. Advances in powder morphology and graded coatings expand use in severe environments while addressing crack resistance and spallation concerns.

Polymers

Polymers support lightweighting and surface functionalization where electrical insulation or friction tuning is needed. Lower heat input techniques and careful surface prep are essential to protect substrates. Market traction benefits from portable systems and standardized primers that stabilize bond strength.

Composites

Composites combine high strength-to-weight with tailored properties, but demand precise thermal management and coefficient-matched coatings. Vendors emphasize process control and non-destructive evaluation to validate interfaces. Adoption is propelled by aerospace and e-mobility programs targeting durability without weight penalties.

Others

Others cover specialty substrates and niche surface states requiring custom surface activation and masking. Solutions are typically engineered-to-order, with pilot trials and iterative recipe tuning. Success relies on close customer collaboration and documentation for repeatability.

Thermal Spray Equipment Market, Segmentation by Operation

The Operation axis spans Automatic, Semi-Automatic, and Manual workflows, reflecting the balance between automation, operator skill, and flexibility. Capacity planners weigh capital cost against OEE, labor availability, and quality consistency. Upgrades increasingly integrate robotics, vision guidance, and closed-loop controls to stabilize processes, reduce scrap, and enable multi-shift production.

Automatic

Automatic systems deliver high repeatability and throughput, ideal for standardized parts and long runs. Benefits include recipe enforcement, automated parameter logging, and reduced operator exposure. They underpin scale-up strategies where consistency and traceability are contractual requirements.

Semi-Automatic

Semi-Automatic cells blend programmed motion with operator oversight, balancing flexibility and cost. They support mixed-model production and faster changeovers. Investment cases often center on incremental productivity gains and phased automation roadmaps.

Manual

Manual operation remains important for complex geometries, low volumes, and repair work. Experienced technicians adjust in real time to part idiosyncrasies, though outcomes depend on skill and training. Safety, ergonomics, and robust PPE practices are essential to mitigate risk.

Thermal Spray Equipment Market, Segmentation by End-User

The End-User lens highlights application intensity and qualification rigor across Aerospace, Automotive, Electronics, Biomedical, Manufacturing, Oil & Gas, and Energy & Power. Procurement emphasizes proven process windows, validated materials, and supplier service coverage. Growth strategies leverage aftermarket services, retrofits, and co-development programs to embed equipment into critical production cells.

Aerospace

Aerospace demands high-spec coatings for thermal barriers, erosion resistance, and oxidation control. Vendors must satisfy rigorous qualification and documentation, making lifecycle support and SPC-driven quality central to supplier selection. Partnerships with engine OEMs and MROs accelerate adoption.

Automotive

Automotive applications prioritize throughput, cost efficiency, and wear performance in components like cylinders, shafts, and EV drivetrains. Standardized cells and high-rate deposition technologies support takt-time goals. Vendor success depends on integration with automation and in-line quality control.

Electronics

Electronics leverages thermal spray for thermal management, EMI shielding, and surface tailoring. Precision, cleanroom adjacency, and low-particulate operation are critical. Equipment roadmaps emphasize fine-feature control, stable feeders, and data connectivity to MES.

Biomedical

Biomedical uses bioactive and porous coatings to enhance osseointegration and implant longevity. Suppliers must meet regulatory requirements and ensure validated, traceable processes. Service offerings include application labs and documentation that de-risk adoption for device manufacturers.

Manufacturing

Manufacturing encompasses general industry needs—anti-wear, corrosion protection, and rebuilds—where flexibility and TCO govern decisions. Modular booths, robust dust control, and easy-to-maintain torches are valued. The outlook favors standardized cells that can pivot across part families.

Oil & Gas

Oil & Gas focuses on erosion-corrosion protection and dimension restoration for valves, pumps, and tubulars. Equipment must withstand harsh environments while delivering consistent bond strength. Adoption correlates with reliability programs and asset integrity mandates.

Energy & Power

Energy & Power includes turbines, boilers, and renewable assets where coatings combat high-temperature attack and particle erosion. Buyers invest in diagnostics, predictive maintenance, and hybrid cells to optimize uptime. Partnerships with EPCs and utilities support fleet-wide rollouts.

Others

Others captures niche sectors deploying coatings for friction control, conductivity, or aesthetics. Solutions are often engineered-to-order with iterative trials. Vendor agility and application engineering are differentiators.

Thermal Spray Equipment Market, Segmentation by Distribution Channel

The Distribution Channel axis differentiates Direct sales—suited to complex, engineered cells—from Indirect channels that expand geographic reach and service density. Customers weigh lead times, field support, and spare parts availability as adoption drivers. Vendors blend key-account management with certified distributors to accelerate expansion while maintaining application expertise.

Direct

Direct channels handle turnkey projects, custom integrations, and qualification-heavy deployments. They offer deep process engineering, training, and lifecycle contracts. This model secures higher share of wallet where reliability and compliance are paramount.

Indirect

Indirect networks extend market coverage for standard equipment, consumables, and aftermarket parts. Authorized partners provide local service response and inventory. Success depends on enablement, documentation, and aligned incentives to sustain quality.

Thermal Spray Equipment Market, Segmentation by Geography

In this report, the Thermal Spray Equipment Market has been segmented by Geography into five regions: North America, Europe, Asia Pacific, Middle East and Africa and Latin America.

North America

North America exhibits strong demand from aerospace, energy, and advanced manufacturing, supported by stringent quality and safety standards. Investment favors automated cells with data logging and validated recipes to meet OEM and MRO requirements. Expansion is bolstered by established integrators, robust aftermarket networks, and sustainability-led replacements of legacy coatings.

Europe

Europe emphasizes ESG compliance, worker safety, and energy efficiency, catalyzing upgrades in booths, dust capture, and HVOF/plasma cells. Proximity to aerospace and industrial clusters supports collaborative R&D and qualification programs. Vendors differentiate via modular cells, digital process control, and lifecycle service agreements.

Asia Pacific

Asia Pacific is characterized by rapid industrialization, localization of supply chains, and growing automotive and electronics bases. The region adopts scalable, cost-optimized equipment with pathway upgrades to automation. Partnerships with local distributors and training centers are central to capturing greenfield opportunities and ensuring process consistency.

Middle East & Africa

Middle East & Africa demand stems from oil & gas, heavy industry, and emerging power investments, focusing on corrosion protection and component life extension. Buyers prioritize ruggedized equipment, reliable gas systems, and service coverage. Growth depends on capability building, supplier training, and fit-for-purpose booth and dust solutions.

Latin America

Latin America features opportunities in mining, pulp & paper, and general industry maintenance where cost-effective repair and rebuild solutions are valued. Vendors succeed by offering modular, serviceable systems, strong indirect channels, and application support that reduces downtime and improves asset reliability. Long-term growth ties to industrial modernization and workforce upskilling.

This report provides an in depth analysis of various factors that impact the dynamics of Thermal Spray Equipment Market. These factors include; Market Drivers, Restraints and Opportunities Analysis

Drivers, Restraints and Opportunity Analysis

Thermal Spray Equipment Market is expanding steadily as manufacturers adopt advanced strategies to improve coating efficiency, durability, and cost-effectiveness. More than 47% of companies emphasize automation, energy efficiency, and precision technologies. Strong collaboration, strategic partnerships, and targeted mergers are reinforcing competitiveness, ensuring continuous growth across aerospace, automotive, and industrial applications.

Market Structure and Concentration
The market reflects moderate concentration, with nearly 52% of share dominated by leading equipment manufacturers and technology providers. Larger firms adopt integrated strategies in R&D and global distribution, while smaller firms introduce niche innovation. This balance supports sustainable growth and long-term expansion across multiple industries requiring advanced surface protection.

Brand and Channel Strategies
Close to 49% of companies strengthen their brand identity by focusing on performance, reliability, and compliance with industry standards. Diverse channel strategies include direct sales, distributor agreements, and digital platforms. Strong collaboration with OEMs and service providers supports market growth and broadens adoption across regions.

Innovation Drivers and Technological Advancements
Nearly 58% of companies are investing in technological advancements such as robotic spraying, plasma systems, and high-velocity oxygen fuel (HVOF) technologies. Innovation aligns with sustainability strategies, reducing waste and energy use. Ongoing partnerships with research institutes and industrial users accelerate growth and enable wider expansion.

Regional Momentum and Expansion
Asia-Pacific accounts for more than 54% of demand, supported by rapid industrial expansion and infrastructure development. Europe emphasizes environmental strategies and regulatory compliance, while North America strengthens collaboration with aerospace and defense industries. Regional partnerships are driving strong growth across advanced manufacturing sectors.

Future Outlook
The future outlook for thermal spray equipment highlights robust growth, with nearly 61% of stakeholders prioritizing digital integration, automation, and eco-friendly strategies. Expanding collaboration, strategic partnerships, and continuous innovation will drive long-term expansion, positioning thermal spray equipment as a vital enabler of high-performance manufacturing.

Key players in Thermal Spray Equipment Market include:

• Oerlikon Metco.
• Praxair Surface Technologies.
• Bodycote.
• Castolin Eutectic.
• Linde PLC.
• Curtiss-Wright Surface Technologies.
• Ador Fontech Ltd.
• A&A Thermal Spray Coatings.
• Alloy Metal Surface Technologies.
• Saint-Gobain S.A.
• Kennametal Inc.
• Lincoln Electric Company.
• BryCoat Inc.
• Camfil Air Pollution Control.
• SprayWerx Technologies Inc.

In this report, the profile of each market player provides following information:

• Company Overview and Product Portfolio
• Market Share Analysis
• Key Developments
• Financial Overview
• Strategies
• Company SWOT Analysis