Thermal Spray Coatings Market To Reach $16.22 Billion By 2033

December 2025 | Report Format: Electronic (PDF)

Thermal Spray Coatings Market Growth & Trends

The global thermal spray coatings market size is expected to reach USD 16.22 billion by 2033, registering a CAGR of 4.7% from 2026 to 2033, according to a new study by Grand View Research, Inc. The global market growth is attributed to the developments in aerospace, automotive, industrial gas turbines, oil & gas, steel, printing, and medical applications. The thermal spray coatings provide electrical/thermal conductivity, enhanced wear resistance, lubricity, chemical resistance, heat resistance, and corrosion resistance to the machine parts. Most of the machine parts are of high value, whose frequent replacement is uneconomical and leads to high costs for the end-user industries.

For example, drilling bits used in mining and offshore drilling operations have to endure the impact of hard terrains and the reaction of undersurface chemicals. The thermal spray coatings provide the required corrosion and wear resistance, which is vital in operations of this magnitude, and can expect a growing consumption due to an increase in metal demand from the automotive and electronics sector. Key manufacturers enter into technological collaborations to enhance the current technologies for better market positioning. For instance, in April 2020, ASB Industries collaborated with the University of Nevada and Akron to develop double-layer coatings on magnesium.

The company’s current cold-sprayed aluminum coatings on magnesium alloys are highly susceptible to localized corrosion in chloride-containing solutions. The ongoing development of a titanium-aluminum coating layer on magnesium raises micro-hardness, thus lowering the wear rate. Such technological collaborations can increase product demand over the coming years. Players in the market are also investing in expanding their manufacturing capabilities. For instance, in March 2021, Oerlikon Metco Coating Services established a world-class additive manufacturing facility in Huntersville, a suburb of Charlotte, North Carolina, to add thermal spray and laser cladding capabilities under one roof.

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Thermal Spray Coatings Market Report Highlights

Ceramics material segment dominated the market with a revenue share of over 32.1% in 2025. This is attributed to the fact that ceramic coatings have excellent adhesion property, which helps them adhere to the surface and provide a thermal barrier, corrosion protection, dielectric strength, and sliding wear resistance to the coated materials.
Plasma spray technology segment dominated the market with a revenue share of over 33.4% in 2025. This process provides the advantage of spraying ceramic and metallic materials onto various surfaces with excellent bond strength while minimizing substrate distortion on both large and small components.
Aerospace in the application segment dominated the market with a revenue share of over 32.0% in 2025. This is attributed that the parts in an aircraft are prone to degradation owing to particle erosion, hot corrosion, metal-to-metal wear, and fretting.
North America dominated the market with a revenue share of over 28.5% in 2025. This is attributable to North America's demand for thermal spray coatings, driven by the growing demand from key industries, including aerospace, oil & gas, automotive, medical, and power generation.