The Global Polymer Thermal Spray Coating Market was valued at USD 9.82 Billion in 2023 and is projected to reach USD 14.65 Billion by 2030, growing at a Compound Annual Growth Rate (CAGR) of 5.8% during the forecast period (2024–2030). This significant growth is driven by increasing demand for corrosion and wear-resistant coatings in aerospace, automotive, and energy sectors, alongside rapid technological advancements in thermal spray processes like cold spray and high-velocity oxygen fuel (HVOF) spraying.

As industries worldwide prioritize asset durability and operational efficiency, the focus intensifies on the key coating solution providers who are pioneering innovative materials and application techniques. In this blog, we profile the Top 10 Companies in the Polymer Thermal Spray Coating Industry—a diverse group of material science leaders and specialized applicators shaping the future of surface engineering.

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🔟 1. Praxair Surface Technologies (Now part of Linde plc)

Headquarters: Indianapolis, Indiana, USA
Key Offering: High-performance coatings, wire and powder materials, coating services

Praxair Surface Technologies, now operating under Linde plc, is a global leader in thermal spray coatings and materials. They supply a comprehensive portfolio of polymer, ceramic, and metal alloy coatings used to protect components in extreme environments across aerospace, industrial gas turbines, and automotive applications. Their expertise spans the entire value chain, from material production to coating application.

Innovation Initiatives:

• Development of advanced polymer-powder composites for superior corrosion resistance

• Investment in robotic automation for precision coating application

• Focus on environmentally compliant coating solutions

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9️⃣ 2. Oerlikon Group

Headquarters: Pfäffikon, Switzerland
Key Offering: Metco coatings, surface solutions, thermal spray equipment

Oerlikon’s Surface Solutions segment is a powerhouse in the thermal spray market, renowned for its Metco brand. They offer a vast array of polymer-based coatings, including thermoplastics and fluoropolymers, known for providing excellent non-stick and low-friction properties. Their solutions are critical for components in the food processing, printing, and textile machinery industries.

Innovation Initiatives:

• R&D in nanostructured polymer coatings for enhanced performance

• Expansion of service centers for regional customer support

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8️⃣ 3. Bodycote plc

Headquarters: Macclesfield, United Kingdom
Key Offering: Thermal spraying, hot isostatic pressing, heat treatment services

Bodycote is one of the world’s largest providers of thermal processing services, including a significant thermal spray coating division. They apply polymer coatings for specific applications requiring chemical resistance and electrical insulation. Their global network of facilities offers coating solutions tailored to the automotive, aerospace, and oil & gas sectors.

Innovation Initiatives:

• Development of integrated thermal spray and heat treatment processes

• Implementation of digital tracking for coating quality assurance

Download FREE Sample Report: Polymer Thermal Spray Coating Market – View in Detailed Research Report

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7️⃣ 4. H.C. Starck GmbH (a Subsidiary of Masan High-Tech Materials)

Headquarters: Munich, Germany
Key Offering: Tantalum and niobium powders, thermal spray powders, additive manufacturing materials

H.C. Starck GmbH is a leading manufacturer of high-performance metal and ceramic powders used in thermal spray processes. While renowned for refractory metals, they also supply polymer powders and composite materials designed for specific thermal spray applications, particularly where high purity and consistent particle size distribution are critical.

Innovation Initiatives:

• Focus on spherical polymer powders for improved flowability in thermal spray guns

• Development of feedstock materials for cold spray technology

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6️⃣ 5. Cincinnati Thermal Spray, Inc.

Headquarters: Cincinnati, Ohio, USA
Key Offering: Thermal spray coating services, metallizing, on-site coating application

Cincinnati Thermal Spray is a specialized service provider with decades of experience in applying protective coatings. They expertly apply polymer coatings such as epoxies, nylons, and fluoropolymers to restore and protect industrial components from abrasion, corrosion, and chemical attack, serving a diverse clientele in manufacturing and heavy industry.

Innovation Initiatives:

• Specialization in large-component and on-site coating applications

• Adoption of advanced surface preparation techniques

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5️⃣ 6. Precision Coatings, Inc.

Headquarters: St. Petersburg, Florida, USA
Key Offering: Engineered coatings, thermal spray, PVD coatings, laser cladding

Precision Coatings is an AS9100 and NADCAP-accredited provider of advanced coating solutions. They offer a range of polymer thermal spray coatings, particularly for aerospace and defense applications where weight reduction and corrosion protection are paramount. Their expertise includes applying coatings to complex geometries and critical turbine engine components.

Innovation Initiatives:

• Investment in state-of-the-art coating application cells

• Development of proprietary polymer blend formulations

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4️⃣ 7. A&A Coatings

Headquarters: Greenville, South Carolina, USA
Key Offering: Thermal spray coatings, abrasive blasting, coating design consulting

A&A Coatings provides comprehensive thermal spray services across North America, with a strong focus on industrial and manufacturing applications. They apply various polymer coatings to protect machinery, rolls, and components in the pulp & paper, printing, and marine industries, helping clients extend equipment life and reduce maintenance costs.

Innovation Initiatives:

• Custom coating development for specific wear and corrosion challenges

• Rapid turnaround services for critical repair operations

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3️⃣ 8. ASB Industries, Inc. (a Kurt J. Lesker Company)

Headquarters: Barberton, Ohio, USA
Key Offering: Thermal spray services, cold spray technology, coating equipment

ASB Industries is a pioneer in advanced thermal spray technologies, with a particular emphasis on cold spray—a solid-state process ideal for heat-sensitive polymer coatings. They are a leader in applying functional coatings for restoration, additive manufacturing, and component enhancement, serving the aerospace, medical, and electronics sectors.

Innovation Initiatives:

• Leadership in cold spray technology development and applications

• R&D in polymer-ceramic composite coatings

Download FREE Sample Report: Polymer Thermal Spray Coating Market – View in Detailed Research Report

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2️⃣ 9. Flame Spray Coating Co.

Headquarters: Houston, Texas, USA
Key Offering: Thermal spray coatings, plasma spray, HVOF, flame spray services

Flame Spray Coating Company offers a wide spectrum of thermal spray processes, including specialized applications for polymer coatings. With a strong presence in the energy and petrochemical sectors, they protect critical infrastructure from the Gulf Coast’s corrosive environment, applying durable polymer coatings to valves, pumps, and structural components.

Innovation Initiatives:

• Expertise in applying thick-film polymer coatings for severe service conditions

• Mobile coating units for field applications in remote locations

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1️⃣ 10. Saint-Gobain Coating Solutions

Headquarters: Worcester, Massachusetts, USA
Key Offering: High-performance abrasives, coatings, refractories, and ceramics

Saint-Gobain, a global leader in material solutions, provides advanced coating technologies through its specialized divisions. Their expertise includes developing and applying polymer-based thermal spray coatings that offer unique combinations of properties like thermal insulation, electrical non-conductivity, and chemical inertness for demanding industrial applications.

Innovation Initiatives:

• Investment in R&D for multi-functional smart coatings

• Development of sustainable and low-VOC coating formulations

Get Full Report Here: Polymer Thermal Spray Coating Market – View in Detailed Research Report

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🌍 Outlook: The Future of Polymer Thermal Spray Coatings is Smarter and More Sustainable

The polymer thermal spray coating market is experiencing a transformative phase. While traditional applications continue to drive volume, the industry is increasingly focused on high-value, engineered solutions that enhance component performance, reduce life-cycle costs, and support sustainability goals.

📈 Key Trends Shaping the Market:

• Accelerated adoption of cold spray technology for temperature-sensitive substrates and additive manufacturing

• Growing demand for bio-based and eco-friendly polymer coatings in response to environmental regulations

• Integration of digital twin technology for predictive coating performance and maintenance scheduling

• Expansion into emerging applications in medical devices, electric vehicle components, and renewable energy systems

Get Full Report Here: Polymer Thermal Spray Coating Market – View in Detailed Research Report

The companies listed above are not merely applying coatings—they are engineering advanced surface solutions that extend the life of critical assets and enable technological progress across industries.