Cold Spray Market (2026-2036)

The growth of this market is mainly driven by the increasing use of cold spray for repair and restoration of high-value aerospace and defense components, rising defense investment in sustainment and expeditionary manufacturing, growing demand for corrosion- and wear-resistant coatings in energy, marine, and industrial applications, and the adoption of cold spray as a high-speed metal additive manufacturing process. In addition, the development of portable and containerized cold spray systems and new powder feedstocks is further supporting the growth of this market.

The Cold Spray Market, also referred to as the cold gas dynamic spray, cold spray coating, or cold spray additive manufacturing (CSAM) market, comprises the equipment, feedstock powders, and services used to deposit metal and composite materials by accelerating solid powder particles to supersonic velocities in a heated gas stream, so that they bond to a substrate through plastic deformation without melting. The market includes high-pressure and low-pressure cold spray systems in stationary robotic cells, portable and handheld units, and containerized expeditionary units; nozzles, gas heaters, and powder feeders; feedstock powders such as aluminum, copper, nickel, titanium, steel, zinc, and metal matrix composites; and coating, repair, and additive manufacturing services. Because cold spray deposits material without melting, it avoids oxidation, phase changes, and heat-affected zones, making it suitable for repairing heat-sensitive components and depositing reactive materials. The market ecosystem extends from gas and powder suppliers to system manufacturers, service providers and depots, research organizations, and end users in aerospace, defense, energy, automotive, electronics, marine, and industrial sectors.

Repair and restoration of high-value components is the largest application of cold spray. Military and aerospace components such as aircraft structures, gearboxes, missile and radar system parts, and vehicle components are often made of magnesium and aluminum alloys that corrode and cannot be repaired by conventional welding without damaging the material. Cold spray allows damaged areas to be rebuilt and returned to service, avoiding the cost and lead time of replacement parts. At the U.S. Army Letterkenny Army Depot, the cold spray program that began in August 2024 had repaired 13 parts by May 2026, generating USD 6 million in direct cost savings on an initial investment of USD 82 thousand, including USD 750 thousand from a single HIMARS cabin floor repair that also reduced downtime by 18 months.

Defense investment is a major source of demand. According to the Stockholm International Peace Research Institute (SIPRI), global military expenditure reached a record USD 2,887 billion in 2025, an increase of 2.9% in real terms, with spending in Europe rising 14% to USD 864 billion and spending across Asia and Oceania rising 8.1% to USD 681 billion. Higher spending is increasing the size and operating tempo of military fleets, and sustainment organizations are adopting cold spray to keep aging equipment in service. The Letterkenny program supports systems including PATRIOT, HIMARS, and THAAD, and is planning on-site repairs in the U.S. Indo-Pacific Command area of responsibility. The U.S. Air Force at Barksdale Air Force Base adopted cold spray in January 2026 to help return B-52H aircraft to flight within scheduled inspection timelines, as some parts for the bomber, which has been in service since 1955, take weeks or months to acquire.

Expeditionary manufacturing is creating a new segment of the market. Cold spray additive manufacturing systems can produce metal parts in hours and can be packaged in shipping containers for deployment near the front line or at sea. The U.S. Department of Defense funded seven SPEE3D cold spray additive manufacturing systems for Ukraine through the Ukraine Security Assistance Initiative in 2023 for maintenance, repair, and salvage of military equipment. In August 2026, SPEE3D reported that its Expeditionary Manufacturing Unit produced eight mission-critical metal parts aboard a vessel underway during the RIMPAC 2026 exercise, the first at-sea deployment of the system.

Cold spray is also used for functional coatings in energy, electronics, and industrial applications. Copper coatings deposited by cold spray have been developed for used nuclear fuel container prototypes in Canada, and cold spray is used for corrosion-resistant zinc and aluminum coatings, wear-resistant coatings, and electrically and thermally conductive coatings on electronics and electric vehicle components. These applications benefit from the low oxide content and dense structure of cold sprayed deposits.

At the same time, the technology is maturing. Deposition rates have increased, with the Army reporting rates of up to 45 kilograms per hour, portable systems allow repairs to be made on site, and new powders and process parameters are expanding the range of materials that can be sprayed. Standards and qualification processes for cold spray repairs are being developed by military and aerospace organizations. Together, these developments are expected to support steady growth of the market throughout the forecast period.

Corrosion is a major driver of maintenance costs across defense, aerospace, energy, and infrastructure, and the U.S. Army notes that corrosion accounts for billions of dollars in annual maintenance. Many legacy systems remain in service far longer than originally planned, as reflected in the B-52H bomber, which has been in service since 1955 and undergoes phase inspections every 450 flight hours or 24 months. Aging fleets with limited spare parts availability create sustained demand for repair technologies such as cold spray that can restore components to service without replacement.

The supply base for cold spray is also expanding. Equipment manufacturers such as Impact Innovations in Germany, Plasma Giken in Japan, CenterLine (SST) in Canada, VRC Metal Systems in the U.S., and SPEE3D and Titomic in Australia offer systems ranging from portable units to high-pressure robotic cells and containerized additive manufacturing systems. Titomic reported revenue of AUD 4.87 million in the first half of 2026 and expects revenue growth for the rest of 2026, with defense, energy, and maritime sustainment among its target sectors. This growing range of suppliers and system types is expected to broaden adoption across industries.

Cold spray also supports sustainability goals, as repairing components rather than replacing them reduces material consumption, energy use, and waste, and cold spray avoids the emissions associated with high-temperature thermal spray processes. These benefits are increasingly important for airlines, defense organizations, and industrial operators seeking to reduce the environmental footprint of maintenance operations.

This reflects the strong economic case for cold spray repair in defense sustainment and the shift toward field-deployable capability.

This indicates that qualification and OEM approval remain the main constraints on growth in aerospace MRO.

This points to growing interest in functional cold spray coatings in energy applications, balanced against operating costs.