The Global Electric Arc Spray Coatings Market was valued at USD 2.84 Billion in 2024 and is projected to reach USD 4.02 Billion by 2030, growing at a Compound Annual Growth Rate (CAGR) of 5.9% during the forecast period (2024–2030). This robust growth is fueled by increasing demand across key industries like aerospace, automotive, and energy for high-performance, durable surface coatings that offer superior corrosion and wear resistance. The market’s expansion is further accelerated by stringent environmental regulations and the shift towards more sustainable and efficient coating technologies.

As global infrastructure and industrial assets face constant degradation from harsh environments, the role of advanced protective coatings has never been more critical. Leading this charge are specialist companies that develop and apply innovative electric arc spray coatings to extend the lifespan and enhance the performance of critical components. In this blog, we profile the Top 10 Companies in the Electric Arc Spray Coatings Industry—a diverse group of thermal spray innovators, equipment manufacturers, and application specialists defining the future of industrial asset protection.

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🔟 1. Oerlikon Metco

Headquarters: Pfäffikon, Switzerland
Key Offering: Arc spray systems, thermal spray powders, coating services

Oerlikon Metco is a global powerhouse in surface solutions, offering a comprehensive portfolio of electric arc spray equipment, consumable wires, and advanced coating services. The company serves a vast array of industries, including aerospace, power generation, and automotive, providing coatings that significantly improve component durability and performance.

Innovation & Sustainability Initiatives:

• Development of high-efficiency arc spray systems for reduced energy consumption

• Extensive R&D into advanced coating materials like MCrAlYs for high-temperature applications

• Commitment to providing environmentally compliant coating solutions

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9️⃣ 2. Praxair Surface Technologies (Now part of Linde)

Headquarters: Danbury, Connecticut, USA
Key Offering: Thermal spray coatings, coating equipment, engineered materials

Following its integration into Linde, Praxair Surface Technologies continues to be a leader in the thermal spray coatings market. The company provides sophisticated electric arc spray technologies and a wide range of metallic and cored wires for applications demanding exceptional wear, corrosion, and thermal protection.

Innovation & Sustainability Initiatives:

• Focus on developing coatings for the aerospace and industrial gas turbine sectors

• Implementation of sustainable manufacturing practices and material recycling programs

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8️⃣ 3. TOCALO Co., Ltd.

Headquarters: Kobe, Japan
Key Offering: Thermal spray coating services, surface treatment solutions

TOCALO is a leading Japanese specialist in surface modification technologies. The company excels in providing high-precision electric arc spray coating services, particularly for the semiconductor, printing, and plastics manufacturing industries, where precision and surface quality are paramount.

Innovation & Sustainability Initiatives:

• Pioneering coatings for semiconductor production equipment to enhance yield and longevity

• Investment in R&D for next-generation, eco-friendly coating materials

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7️⃣ 4. ASB Industries (A Subsidiary of Kurt J. Lesker Company)

Headquarters: Barberton, Ohio, USA
Key Offering: Arc spray systems, HVOF, coating services, and R&D

p>ASB Industries is a renowned provider of thermal spray equipment and contract coating services. The company is highly regarded for its innovative Arc250 and Arc260 electric arc spray systems, which are used globally for applying anti-corrosion and dimensional restoration coatings on large-scale industrial components.

Innovation & Sustainability Initiatives:

• Specialization in custom coating solutions for the marine, pulp & paper, and steel industries

• Development of proprietary cored wires for specialized coating properties

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6️⃣ 5. A&A Thermal Spray Coatings

Headquarters: Houston, Texas, USA
Key Offering: Thermal spray coating services, on-site application, and material sales

A&A Thermal Spray Coatings is a major service provider in North America, offering electric arc spray and other thermal spray processes. The company specializes in both shop-based and field-applied coatings for industries such as oil & gas, power generation, and maritime, focusing on corrosion control and component repair.

Innovation & Sustainability Initiatives:

• Deployment of mobile coating units for on-site repair and maintenance

• Use of zinc and aluminum arc sprays as environmentally preferable alternatives to cadmium coatings

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5️⃣ 6. Falmer Thermal Spray

Headquarters: Waterlooville, United Kingdom
Key Offering: Thermal spray coating services, including electric arc spraying

Falmer Thermal Spray is a key European player specializing in high-quality coating applications. With a strong focus on the aerospace, defense, and manufacturing sectors, the company provides durable electric arc spray coatings that meet stringent international standards for performance and reliability.

Innovation & Sustainability Initiatives:

• Adherence to aerospace quality standards like NADCAP

• Investment in advanced automation for consistent, high-quality coating application

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4️⃣ 7. MBI Coatings (Brand of Metallic Bonds, Inc.)

Headquarters: Torrance, California, USA
Key Offering: Thermal spray powders, wires, and coating services

MBI Coatings is a prominent manufacturer of thermal spray consumables and a provider of coating services. The company offers a diverse range of electric arc spray wires designed for various protective applications, serving customers in the automotive, aerospace, and industrial machinery sectors.

Innovation & Sustainability Initiatives:

• Development of specialized alloy wires for unique wear and corrosion scenarios

• Focus on producing high-purity materials to ensure superior coating performance

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3️⃣ 8. TST Coatings

Headquarters: Solon, Ohio, USA
Key Offering: Thermal spray coating services, laser cladding, and wear solutions

TST Coatings provides advanced surface engineering solutions, with electric arc spraying being a core competency. The company helps clients in demanding industries like mining, steel, and energy to combat extreme wear and extend the service life of high-value machinery and components.

Innovation & Sustainability Initiatives:

• Expertise in combining different thermal spray processes for optimal results

• Implementation of quality management systems to ensure repeatable coating performance

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2️⃣ 9. Plasmajet

Headquarters: Kaisten, Switzerland
Key Offering: Plasma and arc spray systems, automation solutions

Plasmajet is a technology-focused company that designs and manufactures advanced thermal spray systems, including sophisticated electric arc spray equipment. Their solutions are known for precision, reliability, and integration capabilities, making them suitable for both high-volume production and specialized tooling applications.

Innovation & Sustainability Initiatives:

• Development of automated and robotic spray systems for enhanced efficiency and consistency

• Focus on user-friendly controls and data logging for process optimization

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1️⃣ 10. Other Key Regional Players and Specialists

Scope: Global
Key Offering: Niche application services, regional supply chains

Beyond the major global players, the market includes numerous specialized and regional companies that are crucial to the industry’s ecosystem. These firms often dominate specific geographic markets or excel in niche applications, such as coating large structural steel components, architectural elements, or specialized industrial machinery.

Market Role & Contribution:

• Provide essential coating services to local and regional industries

• Drive market penetration and technology adoption in emerging economies

• Offer flexible, customized solutions for small to medium-scale projects

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🌍 Outlook: The Future of Electric Arc Spray Coatings Is Smarter and More Sustainable

The electric arc spray coatings market is evolving rapidly, driven by technological advancements and the ever-increasing need for cost-effective asset protection. While traditional zinc and aluminum coatings remain volume leaders, the industry is heavily investing in advanced materials, process automation, and digital integration to meet the demands of modern manufacturing and infrastructure maintenance.

📈 Key Trends Shaping the Market:

• Rising adoption of cored wires for tailored coating properties and enhanced performance

• Integration of robotics and automation for improved coating consistency, reduced waste, and enhanced worker safety

• Growing demand from the renewable energy sector (e.g., coatings for wind turbine components and hydroelectric structures)

• Stringent environmental regulations promoting the use of electric arc spray as a solvent-free, high-solid coating alternative

The companies listed above are not just supplying coatings; they are delivering integrated solutions that enhance the longevity, safety, and efficiency of industrial and consumer assets worldwide. Their continuous innovation ensures that electric arc spray technology remains a vital tool for sustainable asset management.

Get Full Report Here:
Global Electric Arc Spray Coatings Market – View in Detailed Research Report