US Thermal Spray Coating Equipment and Services Market Outlook 2025-2035
The US Thermal Spray Coating Equipment and Services Market is witnessing robust growth, fueled by advancements in coating technologies and the rising demand from sectors like aerospace, automotive, and oil & gas. As industries increasingly focus on enhancing surface protection and performance, thermal spray coatings offer vital solutions for improved durability, efficiency, and longevity, driving market expansion. With key innovations in automated and robotic coating systems, and the growing presence of major vendors, the US market is poised for promising growth opportunities over the forecast period.
Latest Market Dynamics
Key Drivers
Rising adoption of thermal spray coatings in aerospace and automotive sectors to enhance component lifespan and efficiency; for example,
Technological advancements in robotic and automated spray equipment, increasing productivity and precision, as highlighted by Curtiss-Wright’s investment in smart coating solutions.
Key Trends
Growing shift towards environmentally friendly coating solutions, such as low-VOC and cold spray technologies. Recent developments by Praxair Surface Technologies emphasize eco-friendly product launches.
Integration of Industry 4.0 and IoT in thermal spray equipment for real-time monitoring and process control. Bodycote plc has developed digital interfaces improving service transparency.
Key Opportunities
Expansion of applications in electronics and medical devices, leveraging precision thermal spray techniques; Plasma-Tec Inc recently launched new product lines targeting medical device manufacturers.
Increasing demand for repair and maintenance services across industrial gas turbines and energy segments, as shown in United Coatings Technologies’ recent service contracts with power plants.
Key Challenges
High initial capital investment required for advanced spray systems, presenting adoption barriers for small and medium enterprises (SMEs), with smaller vendors in the US citing financing constraints.
Stringent regulations regarding the environmental impact of coating processes, requiring companies like Saint-Gobain to invest in cleaner, compliant technologies.
Key Restraints
Volatility in prices of raw materials such as feedstock powders and gases, impacting cost control for firms like Flame Spray Technologies BV.
Supply chain disruptions leading to delayed project timelines and increased operational costs, with Tocalo Corporation reporting notable delays in equipment delivery.
US Thermal Spray Coating Equipment and Services Market Share (%) by Type, 2025
In 2025, plasma spray technology constitutes the largest share of the US market, followed closely by HVOF and flame spray methods. This dominance is attributed to plasma spray’s superior versatility and ability to deposit a wide range of materials with high bond strength, making it preferred in high-performance sectors. Meanwhile, high-velocity oxy-fuel (HVOF) is attracting greater adoption in aerospace and industrial gas turbine applications due to its enhanced wear and corrosion resistance. Although flame spray holds a substantial portion, newer methods like cold spray are gradually gaining traction for specialized applications. The increasing emphasis on automated processes and novel material compatibility drives ongoing shifts in the market structure.
US Thermal Spray Coating Equipment and Services Market Share (%) by Applications, 2025
Aerospace leads in application share for the US thermal spray coating market in 2025, making up nearly one-third of total demand due to the sector’s critical needs for high-performance, heat and corrosion-resistant coatings. Industrial gas turbines and automotive follow, leveraging thermal sprays for component protection and life extension. Electronics and medical devices exhibit increased adoption, demonstrating the expanding role of precision coatings in these industries. The spread of applications underscores how thermal spray offers cross-sectoral value, from enhancing jet engine parts to protecting medical implants and sensitive electronics.
US Thermal Spray Coating Equipment and Services Market Revenue (USD Million), 2020-2035
The US thermal spray market is projected to witness a strong growth trajectory between 2020 and 2035, driven by rapid industrialization and an increasing shift to advanced coating technologies. Revenue is estimated to grow from $1,320 million in 2020 to $2,825 million by 2035. The period from 2025 to 2030 is expected to see the highest CAGR, as investments in aerospace, energy, and medical applications accelerate. Sustained demand for efficient surface treatments and maintenance solutions fuels this upward trend, despite cyclical fluctuations in some end-use sectors.
US Thermal Spray Coating Equipment and Services Market YOY Growth (%), 2020-2035
Year-on-year (YOY) growth in the US thermal spray market is anticipated to peak between 2025 and 2030, reaching up to 6.5% annually, before stabilizing as the market matures and penetrates emerging sectors. Earlier years show moderate growth attributed to market recovery post-pandemic and gradual adoption of new technologies. From 2030 onwards, growth moderates to around 4% as market saturation increases. These trends reflect the interplay between innovation, industry demand, and economic cycles.
US Thermal Spray Coating Equipment and Services Market Share (%) by Regions, 2025
The South and Midwest lead the regional market share for US thermal spray coatings in 2025, supported by the concentration of manufacturing hubs, aerospace, and energy industries. The West follows, with significant contributions from electronics and high-tech sectors in California. The Northeast, while smaller, still plays a vital role in medical devices and specialty equipment. Regional shares highlight the importance of location-specific industry bases, workforce skills, and investment climates in shaping the market.
US Thermal Spray Coating Equipment and Services Market Players Share (%), 2025
Oerlikon Metco maintains the largest share in the US thermal spray coating market for 2025, due to its comprehensive product range and strong partnerships across major industries. Praxair Surface Technologies and Bodycote plc form the next leading group, leveraging specialized services and innovative product launches. Mid-tier players like Plasma-Tec Inc and Curtiss-Wright Corporation are gaining ground with industry-specific solutions. The market is moderately fragmented, as smaller and niche-focused suppliers carve out roles in high-value segments.
US Thermal Spray Coating Equipment and Services Market Buyers Share (%), 2025
Aerospace OEMs and MRO providers account for the largest portion of buyers in the US thermal spray market, followed by industrial gas turbine operators and automotive manufacturers. Medical device companies and electronics producers form a sizeable emerging segment, reflecting the market’s expanding scope. This buyer composition underscores the market’s alignment with high-growth, technology-driven industries seeking advanced surface protection and enhancement solutions.
Study Coverage
Metrics
Details
Years
2020-2035
Base Year
2025
Market Size
Revenue (USD Million)
Regions
South, Midwest, West, Northeast
Segments
By Type (Flame Spray, Arc Spray, Plasma Spray, High-Velocity Oxy-Fuel (HVOF), Cold Spray, Others), By Application (Aerospace, Industrial Gas Turbine, Automotive, Electronics, Oil & Gas, Medical Devices, Others), By Distribution Channels (Direct Sales, Distributors, E-commerce, System Integrators, Value-Added Resellers, Others), By Technology (Manual, Semi-Automatic, Automatic, Robotic, Portable, Others), By Organization Size (Small, Medium, Large)
June 2024: Oerlikon Metco announces new plasma spray technology partnership with major US aerospace OEM.
July 2024: Praxair Surface Technologies launches eco-friendly HVOF product line targeting industrial gas turbines.
August 2024: Curtiss-Wright debuts advanced robotic spray equipment, enhancing process automation.
August 2024: Bodycote plc integrates IoT capabilities within its US coating centers, enabling real-time analytics.
September 2024: Plasma-Tec Inc secures new medical device coating contracts with leading healthcare OEMs.
Frequently Asked Questions
About the Author
Abhishek
Senior Market Research Analyst
Abhishek is a Senior Market Research Analyst specializing in market research, industry analysis, and business consulting across Chemical & Material. Abhishek brings a commercially grounded perspective to sectors shaped by changing demand, innovation, and competitive dynamics, helping turn complex market trends into clear strategic insights for business decision-makers. With 10+ years of experience across research, analytics, and strategic advisory roles, Abhishek has helped organizations translate data into actionable growth strategies.
Chemical & MaterialMarket ResearchIndustry AnalysisStrategic Consulting
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