According to IDTechEx analyst Lily-Rose Schuett, advances in coatings, graphene and critical material recovery are reshaping the global materials landscape, with growing demand for sustainable, high-performance solutions across sectors ranging from aerospace and EV batteries to energy and data centres.
In her analysis, “The Top of the Material Chain – Advanced Coatings to Critical Minerals”, Schuett highlights how advanced coatings are increasingly being adopted to improve durability, efficiency and safety. Citing IDTechEx research, she notes that the coatings market is currently valued at around US$202bn, with Germany, China and the US leading exports. Demand is being fuelled by industries seeking lightweight materials capable of withstanding extreme temperatures, particularly in aerospace and energy applications.
Schuett explains that advanced coatings are also being developed with sustainability in mind, as environmental regulations and consumer expectations push manufacturers towards PFAS-free and heavy metal-free alternatives. Applications highlighted in the research include improving fire safety in EV batteries, aerospace systems and data centres, while also reducing maintenance requirements in sectors such as wind energy, oil and gas, and construction.
The report further identifies manufacturing efficiency, coating performance and sustainability as the three main priorities shaping coating development. Desired properties include long shelf life, low viscosity, short curing times and lightweight composition, although balancing performance with sustainability remains application dependent.
Schuett also explores developments in graphene and other advanced materials. Graphene, a 2D nanocarbon material, is valued for its exceptional strength, thermal conductivity, electrical properties and gas impermeability. It is increasingly being used in thermal management systems, conductive inks, sensors, membranes, concrete and asphalt applications.
However, she notes that maintaining graphene quality remains a challenge, as pristine graphene sheets must be carefully transferred from their growth substrate to the final application without damage. Future developments may include genuine monolayer and bilayer graphene additives, as well as more sustainable production methods using green or waste-derived feedstocks such as methane, coke and end-of-life lithium-ion batteries.
According to Schuett, competition from materials such as carbon black and carbon nanotubes remains strong, yet the graphene sector continues to expand. IDTechEx forecasts the graphene market will surpass US$1bn by 2032, with continued growth expected over the following decade.
The analysis also examines the growing importance of critical material recovery as geopolitical tensions and supply chain risks increase pressure on global access to strategic materials. Critical materials, which include metals, elements and composites essential to key industries, are becoming increasingly important as countries seek greater supply security.
Schuett outlines several extraction and recovery methods covered in IDTechEx research, including hydrometallurgy, pyrometallurgy, electro-leaching, solvent extraction, ion exchange, biosorption and electro-winning. Established secondary sources for material recovery include platinum group metals from automotive emission control systems, while emerging opportunities are centred on lithium-ion batteries and rare-earth magnets from EVs.
The report also evaluates extraction technologies based on factors such as scalability, energy consumption, waste-source versatility and circularity, reflecting the increasing emphasis on sustainability within the critical materials sector.
Advanced materials drive sustainable innovation
