Top Thermal Spray Companies

The global thermal spray market is driven by growing automotive manufacturing and increasing R&D investments in thermal spray technologies. Advancements in material technologies and material science are also slated to boost the sales of thermal spray. Robust increase in industrialization around the world and the need for better coatings are also promoting the adoption of thermal spray. Thermal spray provide such protection, extending parts’ lifespan, improving reliability, and reducing maintenance or replacement costs. Growth of renewable energy infrastructure (wind, solar, power plants) increases need for protective coatings that can endure extreme environmental and thermal cycling

Industry Overview

According to SkyQuest Technology “Thermal Spray Market By Product Type (Metal, Ceramics, Intermetallic, Polymers, Carbides, Abradable, Others), By Process/Technology (Combustion Flame, Electric Energy, Others), By Function, By End User, By Region - Industry Forecast 2025-2032,” Global thermal spray market is projected to grow at a CAGR of over 5.1% by 2032, as advances in spraying techniques  and development of new materials pick up pace. Rising manufacturing activity in Asia-Pacific, Latin America, and Africa regions is also slated to create new opportunities for market players. Surging investments in healthcare and aerospace sectors is also slated to create new business scope for thermal spray companies in the long run.

Top 10 Global Thermal Spray Companies

1. Bodycote

The company is considered a global leader in thermal processing services, including thermal spray and heat treatment. Bodycote’s advanced plasma and HVOF (High Velocity Oxy-Fuel) coating technologies ensure optimized surface performance even in extreme conditions. The company has extensive experience and expertise in aerospace, automotive, power generation, and engineering sectors. By integrating digital quality control, process automation, and sustainability-focused material development, the company is slated to ensure its dominance in the industry over the coming years.

2. Tencarva Machinery Company

Tencarva Machinery Company is popularly known for supplying engineered industrial and environmental equipment. Tencarva’s integration of spray coating systems into its machinery offerings ensures greater reliability and corrosion resistance in challenging industrial environments. Despite the company being known for fluid-handling systems and process machinery, its expertise in advanced coating systems and thermal spray technologies make it a key player. By focusing on customer service, precision engineering, and system performance optimization, Tencarva strengthens its role in enhancing equipment longevity through advanced surface technologies.

3. Oerlikon Metco

This Swiss giant is known around the world for its expansive experience in surface engineering and thermal spray coating technologies. The company is part of the larger Oerlikon Group, allowing it to serve a wide array of verticals. Oerlikon Metco’s innovations include plasma, HVOF, and arc spray systems designed to extend component lifespan and reduce maintenance costs. Its materials portfolio encompasses metallic and ceramic powders optimized for thermal performance. The company focuses on investing in additive manufacturing and digital production systems to enhance its business scope.

4. Praxair Surface Technologies (now part of Linde)

Praxair Surface Technologies has an established legacy of delivering superior coating and surface solutions to industrial clients around the world. The company is now integrated with Linde. High-performance thermal spray, wear-resistant materials, and surface restoration solutions have allowed the company to emerge as a key player on a global level. Praxair’s global coating centers employ advanced HVOF, plasma, and flame-spray processes. As part of Linde, the company leverages synergies in gas supply and materials science to optimize coating performance.

5. Sulzer Metco

Part of the larger Sulzer Group, the company is seen as one of the early pioneers of thermal spray and coating technologies. Sulzer Metco focuses on performance reliability, product innovation, and technical expertise, providing materials that extend equipment lifespan. The firm’s collaboration with OEMs ensures custom-engineered coating solutions for specific operational challenges. The company’s advanced plasma and flame-spray technologies are expected to help it stay competitive in the global landscape going forward.

6. H.C. Starck Surface Technology and Ceramic Powders

Based out of Germany, the company benefits from the robust chemical and industrial base of the country to emerge as a key thermal spray provider. Starck’s coating materials and powders are integral to thermal spray applications, improving hardness, wear resistance, and corrosion protection in demanding industrial environments. The company is also leveraging the sustainability trend to promote the use of recyclable and eco-friendly materials. By combining advanced powder metallurgy and coating technology, H.C. Starck reinforces its reputation as a global leader in materials science and surface performance enhancement.

7. Sandvik Materials Technology

Part of the massive Sandvik Group, the company is popularly known for offering advanced materials and thermal spray solutions. Sandvik’s proprietary materials and coatings are utilized in sectors like mining, aerospace, and energy. Robust R&D spending of Sandvik in powder metallurgy is also allowing this company to stay competitive. The company’s focus on process optimization, additive manufacturing, and surface protection has made it a critical player in advancing coating technologies that promote efficiency, longevity, and industrial resilience worldwide.

8. GTV Verschleißschutz GmbH

The German company specializes in the development and manufacture of thermal spray systems and coating services. Operating primarily in the industrial sectors, the company’s expertise spans across HVOF, plasma, and arc spray technologies. GTV provides turnkey coating systems and tailored materials to industries such as energy, aerospace, and mechanical engineering. The company is actively investing in R&D to optimize coating adhesion and performance, which can help it maintain its stance as a key innovator of thermal spray.

9. Thermal Coating Services

Thermal Coating Services, founded in 1985 and headquartered in Coventry, United Kingdom, is a trusted provider of industrial coating and surface restoration services. The company offers comprehensive solutions including HVOF, plasma, and combustion spray technologies tailored for aerospace, oil and gas, and manufacturing sectors. Thermal Coating Services emphasizes process precision and quality assurance, ensuring optimal coating thickness and adhesion. Its investment in modern coating equipment and sustainability practices enhances efficiency and performance. By delivering reliable, high-quality coatings, Thermal Coating Services continues to strengthen its role in the UK’s advanced manufacturing and repair industry.

10. Tafa Surface Technologies

The company is known for its innovative plasma and arc spray systems, which provide superior surface protection for components exposed to wear, heat, and corrosion. Tafa’s product portfolio includes complete coating systems, powder materials, and support services for industries such as aerospace, automotive, and power generation. Its equipment is recognized for reliability, ease of integration, and consistent coating quality. Through ongoing research and technical collaboration, Tafa Surface Technologies continues to drive advancements in coating precision, efficiency, and sustainability.

Other Leading Global Thermal Spray Companies

• Saint-Gobain
• Metallisation Group
• Chromalloy

Conclusion

The global thermal spray market is anticipated to expand at an modest CAGR but can face challenges due to factors such as high costs of production and process limitations. Despite these challenges, growing emphasis on sustainability among consumers is slated to boost the demand for thermal spray going forward. Advancements in additive manufacturing technologies and high investments in material science R&D and growing investments in thermal sprays are also forecasted to create new business scope for market players. Industrialization is slated to remain the constant factor driving sustained demand for thermal spray on a global level.