Thermal Spray Coatings Market Size, Share, Growth Analysis, By Process(Combustion flame (wire flame spraying, powder flame spraying, detonation gun spraying, ceramic rod spraying), By Material(Metal and Alloys, and Ceramics), By End user(Aerospace (flame tubes, turbine blades, landing gear), Automotive (suspension parts), By Region - Industry Forecast 2025-2032

Thermal Spray Coatings Market size was valued at USD 11.87 Billion in 2023 and is poised to grow from USD 12.46 Billion in 2024 to USD 18.41 Billion by 2032, growing at a CAGR of 5.0% during the forecast period (2025-2032).

The utilization of thermal spray coatings in various industries such as automotive, aerospace, medical, industrial gas turbine, printing, steel, and pulp & papers plays a significant role in driving market growth. The increasing application of gas turbines in helicopter engines, tanks, ships, and locomotives is projected to boost the demand for thermal spray coatings. These coatings possess excellent resistance to high temperatures and corrosion, providing protection against fire in environments characterized by elevated temperatures and moisture levels. Furthermore, these offer desirable properties such as resistance to wear caused by abrasion, cavitation, and erosive forces, as well as chemical resistance, electrical insulation, and improved adhesion between substrate and components' top layers.

The strict regulations implemented by regulatory bodies like the U.S. Environmental Protection Agency (EPA), Registration, Evaluation, Authorization and Restriction of Chemicals (REACH), and Occupational Safety and Health Administration (OSHA) have compelled coating manufacturers to adopt sustainable solutions. This shift away from hard chrome plating, which generates a carcinogenic byproduct, has resulted in an increased adoption of thermal spray coatings across various industries. In terms of regional market revenue, the United States holds the largest share in North America attributed to the substantial demand for industrial gas turbines from power generation plants. The U.S. government's policy transition towards replacing coal with natural gas for electricity generation is expected to drive the demand for gas turbines. Additionally, the growing elderly population and advancements in healthcare services in the U.S. are anticipated to contribute to the expansion of the orthopaedic implant market, particularly for kneecap replacement surgery.