How big is the Thermal Spray Market | Insights, Forecast & Growth 2025

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Code: MTA9347

Publication Date: Sep 2025

What is the size of Thermal Spray Market?

According to 6Wresearch internal database and industry insights, the Global Thermal Spray Market was valued at USD 13.9 billion in 2024 and is expected to reach USD 20.2 billion by 2031, growing at a compound annual growth rate of 5.6% during the forecast period (2025-2031).

The primary factors driving this growth include increases in demand from the aerospace and automotive industries, growth in the adoption of medical implants, and advancements in coating technologies to improve surface durability and wear resistance, and protection from corrosion.

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Growth Factors for Thermal Spray Industry

Continued increase in the use of thermal spray coatings in aerospace turbine and engine components.
Increase in demand from automotive applications to improve wear resistance and performance in heat.
Increased awareness of biocompatible coating for medical implants and devices.
Growth in demand for energy, oil, and gas sectors to prevention corrosion.
Advancements in plasma and high-velocity oxygen fuel spray technologies.

Thermal Spray Market Trends

The thermal spray market trends indicate continued increases in adoption across industries seeking high-performance coatings for protection and durability. Notably ceramic-, polymer-, and carbide-based coatings are becoming increasing usages with better resistance to heat, wear, and corrosion. Though some industries such as aerospace and automotive, and power generation industries are increasing the usage of coatings, manufacturers are developing new automation and robotics to create better coating processes for precision. The use of eco-friendly spray materials is driving investment in sustainable surface engineering.

Emerging Developments in the Thermal Spray Market

The thermal spray market developments are focused on improving efficiency, sustainability, and application flexibility. Companies are investing in advanced plasma spray systems and hybrid technologies to meet evolving industrial requirements. Developments also include expansion into additive manufacturing processes, where thermal spray is used for 3D coating applications. Additionally, thermal spray service providers are enhancing maintenance solutions for critical infrastructure, while industries such as healthcare and electronics are opening new opportunities for specialized coating innovations.