01 Cold Spray Moving Into Component Repair and Remanufacturing The need to restore expensive metal components without exposing them to high thermal stress is strengthening the role of cold spray in repair and remanufacturing. This shift is positioning cold spray as a precision repair process for restoring damaged geometry, rebuilding localized material loss, and repairing temperature-sensitive metal components without melting the substrate. The U.S. Army has reported cold-spray deposition rates of up to 45 kg per hour for selected repair applications, showing its potential for faster restoration of high-value components.
02 Thermal and Environmental Barrier Coatings Moving Toward Extreme-Temperature Applications Higher operating temperatures in aircraft engines, gas turbines, and advanced propulsion systems are placing greater performance pressure on conventional protective coatings. This condition is shifting development toward advanced thermal and environmental barrier coatings that protect ceramic-matrix composites and other heat-sensitive materials under severe thermal and corrosive conditions. NASA continues to develop plasma-sprayed coating systems for extreme-temperature aerospace environments, reflecting the expanding role of thermal spray in next-generation engine protection.
01 Longer Service Life Requirements for Industrial Components and Higher Use of Wear- and Corrosion-Resistant Coatings in Manufacturing Drive Market Longer equipment life targets increase demand for thermal spray coatings that protect high-value components from surface degradation during continuous operation. Industries such as aerospace, power generation, mining, and oil & gas use coated parts to lower lifecycle maintenance costs and keep critical equipment operational for longer periods between major overhauls. Gas turbine operators, for example, apply thermal spray coatings to turbine blades and other critical parts to improve durability under demanding operating conditions. Harsh operating environments involving abrasive particles, chemical exposure, friction, and corrosive media make surface protection a critical requirement across process and production equipment. Manufacturers use thermal spray materials such as carbides, ceramics, and metallic alloys to protect pumps, rollers, shafts, valves, and processing components. Broader use of protective coatings therefore expands demand for coating materials, spraying equipment, and contract coating services across manufacturing industries.
01 High Equipment and Operating Costs and Need for Skilled Operators & Process Control Restrain Market Expansion High capital costs for spray guns, robotic systems, ventilation equipment, surface-preparation tools, and power systems increase the financial burden of thermal spray operations. Ongoing expenses for gases, energy, maintenance, and specialty feedstock further raise production costs for coating providers. This cost structure limits adoption among smaller manufacturers and slows wider market penetration.Specialized knowledge is required to control spray temperature, particle velocity, feed rate, surface preparation, and coating thickness. Limited availability of trained operators can create inconsistent coating quality, rework, and higher production costs. This dependence on technical expertise restricts capacity expansion and slows adoption across less-developed manufacturing environments.
01 Expansion in Renewable Energy and Medical Implant Applications Offers Growth Opportunities Thermal spray coating providers, wind turbine manufacturers, and renewable energy equipment suppliers can benefit from coating solutions for shafts, bearings, towers, and other exposed components. These applications can create revenue through specialized coating contracts, refurbishment services, and long-term maintenance programs across wind and other clean-energy assets. Companies such as Oerlikon and Bodycote already serve energy-related surface engineering applications.Coating manufacturers, orthopedic device companies, and medical implant producers can benefit from thermal spray technologies used to improve implant surface properties and fixation performance. Medical applications can open higher-margin revenue through titanium and hydroxyapatite coating services, customized implant programs, and regulated manufacturing partnerships. Companies such as Oerlikon and Lincotek are active in surface treatments and coatings for orthopedic and medical devices.
01 Lengthy Qualification and Customer Approval Cycles and Maintaining Consistent Feedstock Quality and Availability Hinders Growth Thermal spray coatings used in aerospace, energy, and other high-performance applications must pass extensive testing, documentation, and customer-specific qualification before commercial use. These approval cycles delay new coating introductions and make it harder for smaller suppliers to enter regulated applications. AWS standards include formal requirements for procedure qualification, inspection, documentation, and coating-system approval, reflecting this operational burden.Coating performance depends heavily on powder and wire characteristics such as particle size, chemistry, density, and flow behavior, making reliable feedstock sourcing essential. Variations between suppliers or batches can force additional testing and restrict manufacturers from scaling standardized coating solutions across facilities. The 2025 AWS thermal spray powder specification introduced detailed requirements covering particle distribution, composition, manufacturing, labeling, and packaging, highlighting the importance of feedstock consistency.
June 2026 John Cockerill India inaugurated its new Rolls Coating Facility at Taloja, Maharashtra, India to expand its value-added surface engineering capabilities for the steel industry. The facility is equipped with new-generation HP-HVAF (High Pressure High Velocity Air Fuel) thermal spray coating technology and provides roll coating, grinding, finishing, balancing, inspection, and quality control services. The company stated that the facility will support steel producers by improving roll life, reducing maintenance downtime, and enhancing operational performance.
September 2025 Oerlikon began construction of its new Campus Reichhold innovation and production hub in Aargau, Switzerland, dedicated to thermal spray systems and coating services. The facility will consolidate research and development, engineering, production, and customer service operations from multiple Swiss locations. Oerlikon stated that the center will support next-generation thermal spray technologies and serve aerospace, automotive, and industrial customers.
May 2025 Oerlikon announced its investment in the Campus Reichhold facility with a CHF 40 million commitment to establish an integrated innovation and production center for thermal spray systems and coating services. The company highlighted that the new hub will include advanced testing capabilities for aerospace turbine coating systems.
January 2025 (facility operational update announced in February 2025): Oerlikon inaugurated its Smart Integrated Surface Solutions Centre in Tumakuru, Karnataka, India. The center provides integrated surface solutions, including thermal spray applications, tool coatings, and automotive component coating services. The company stated that the investment strengthens its surface engineering capabilities in India.