The Global Thermal Spray Wires Market was valued at USD 1.11 Billion in 2022 and is projected to reach USD 1.74 Billion by 2029, growing at a Compound Annual Growth Rate (CAGR) of 6.6% during the forecast period (2023–2029). This robust growth is driven by increasing demand from aerospace, automotive, and heavy machinery sectors for advanced coating solutions that enhance component longevity, resist corrosion, and improve thermal performance across critical applications.

As industrial manufacturing evolves toward greater efficiency and sustainability, the spotlight is on the key material suppliers driving innovation in surface engineering. In this blog, we profile the Top 10 Companies in the Thermal Spray Wires Industry—a mix of global material science leaders, specialized manufacturers, and technology innovators shaping the future of protective coatings.

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🔟 1. Oerlikon Metco

Headquarters: Pfäffikon, Switzerland
Key Offering: Comprehensive portfolio of thermal spray wires, powders, and coating systems

Oerlikon Metco is a global leader in surface solutions, providing a wide array of thermal spray wires for wear resistance, thermal barrier coatings, and corrosion protection. Their products are critical in industries ranging from aviation to power generation, supported by extensive R&D and application expertise.

Innovation and Sustainability Initiatives:

• Development of advanced alloy wires for high-temperature applications

• Focus on coatings that extend component life and reduce environmental footprint

• Global technical support and customized coating solutions

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9️⃣ 2. Kanthal

Headquarters: Hallstahammar, Sweden
Key Offering: High-temperature heating elements and specialty alloy wires

Part of the Sandvik Group, Kanthal is renowned for its expertise in resistive and electric heating technologies. Their thermal spray wires are engineered for extreme environments, offering superior oxidation resistance and durability in industrial heating and processing equipment.

Innovation and Sustainability Initiatives:

• Pioneering iron-chromium-aluminum (FeCrAl) alloy wires

• Commitment to energy-efficient industrial heating solutions

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8️⃣ 3. Metallisation

Headquarters: Dudley, United Kingdom
Key Offering: Arc spray and thermal spray wires, equipment, and services

Metallisation specializes in metal spraying technology, offering a range of wires for anti-corrosion, dimensional restoration, and conductive coatings. The company provides integrated solutions, including application equipment and on-site services for various industrial sectors.

Innovation and Sustainability Initiatives:

• Specialization in zinc and aluminum wires for cathodic protection

• Development of portable spray systems for field maintenance

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7️⃣ 4. Polymet Corporation

Headquarters: Ann Arbor, Michigan, USA
Key Offering: Thermal spray powders and wires for wear and corrosion control

Polymet Corporation is a key North American supplier of thermal spray consumables. The company focuses on providing high-quality wires for rebuilding and protecting components in demanding environments, such as mining, steel, and pulp and paper industries.

Innovation and Sustainability Initiatives:

• Customer-specific alloy development

• Emphasis on reducing downtime through effective refurbishment coatings

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

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6️⃣ 5. Tankii

Headquarters: Shanghai, China
Key Offering: Thermal spray wires, powders, and welding consumables

Tankii is a prominent Chinese manufacturer of thermal spray materials, serving both domestic and international markets. The company offers a cost-effective range of wires for various thermal spray processes, catering to the growing industrial base in Asia-Pacific.

Innovation and Sustainability Initiatives:

• Expansion of product lines to include advanced composite wires

• Focus on supplying the booming Asian infrastructure and manufacturing sectors

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5️⃣ 6. Parat Tech

Headquarters: Senden, Germany
Key Offering: Specialized wires for arc spraying and flame spraying

Parat Tech is a German specialist in thermal spray wires, with a strong focus on quality and precision. Their products are used for applying protective coatings on machinery components, rolls, and structural parts across European industries.

Innovation and Sustainability Initiatives:

• High-purity wire manufacturing for consistent coating quality

• Adherence to stringent European quality standards

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4️⃣ 7. Flame Spray Technologies BV

Headquarters: Rotterdam, Netherlands
Key Offering: Combustion wire spray systems and consumables

Flame Spray Technologies BV is a leading supplier of thermal spray equipment and wires, particularly for the flame spray process. The company serves a global clientele in oil & gas, marine, and heavy equipment industries with robust coating solutions.

Innovation and Sustainability Initiatives:

• Integration of wire spray systems with robotic automation

• Solutions for in-situ component repair, reducing waste and resource use

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3️⃣ 8. Praxair Surface Technologies

Headquarters: Indianapolis, Indiana, USA
Key Offering: Thermal spray materials, including wires, powders, and equipment (now part of Linde)

Praxair Surface Technologies, now operating under Linde, is a major global supplier of advanced coating materials. Their thermal spray wires are extensively used in the aerospace industry for coating turbine blades, landing gear, and other critical components.

Innovation and Sustainability Initiatives:

• Development of abradable and wear-resistant coatings for aerospace

• Research into coatings that improve fuel efficiency and reduce emissions

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2️⃣ 9. Plasma Powders & Systems, Inc.

Headquarters: Somerset, New Jersey, USA
Key Offering: Thermal spray powders, wires, and custom coating services

Plasma Powders & Systems, Inc. is a US-based manufacturer specializing in materials for plasma and HVOF spraying. The company provides a variety of wires designed for high-performance coatings in the defense, aerospace, and industrial sectors.

Innovation and Sustainability Initiatives:

• Custom alloy development for specific customer applications

• Focus on coatings that enable remanufacturing and parts reuse

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1️⃣ 10. United Coatings Technologies

Headquarters: Green Bay, Wisconsin, USA
Key Offering: Thermal spray wires, powders, and application services

United Coatings Technologies is a specialized provider of thermal spray consumables and contract coating services. The company offers a range of wires for applications requiring high wear resistance, such as in the printing, packaging, and automotive industries.

Innovation and Sustainability Initiatives:

• Expertise in applying coatings for roll surfacing and machinery components

• Commitment to improving product lifecycle through advanced surface engineering

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Thermal Spray Wires Market – View in Detailed Research Report

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🌍 Outlook: The Future of Thermal Spray Wires Is High-Performance and Sustainable

The thermal spray wires market is undergoing a significant transformation. While traditional steel and alloy wires continue to dominate volume, the industry is increasingly focused on advanced material formulations that offer superior performance, longer service life, and environmental benefits.

📈 Key Trends Shaping the Market:

• Rising demand for lightweight and high-strength coatings in aerospace and automotive applications

• Growth in remanufacturing and repair services, driving demand for restoration-grade wires

• Development of composite and cored wires for multifunctional coatings

• Increasing adoption of automated and robotic thermal spray systems, requiring consistent wire quality

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

The companies listed above are not only supplying essential materials for industrial maintenance and manufacturing—they’re driving the innovation in surface engineering that protects critical assets and extends their operational life.