Plasma: The Fourth State of Matter Revolutionizing Industry
Discover how plasma technology is transforming industries from healthcare to manufacturing with innovative applications in surface treatment, powder processing, and metallurgy.
Imagine a substance that is neither solid, liquid, nor gas, capable of sterilizing wounds without antibiotics, cleaning semiconductors with nanometer precision, or treating metal powders for 3D printing. This mysterious substance is not science fiction: it is plasma, this particular state of matter that underpins technologies increasingly present in our daily lives and industry. Representing more than 99% of visible matter in the universe, plasma was until recently confined in the collective imagination to lightning during storms or plasma screens. Today, mastered in laboratories and factories, it opens the way to unsuspected industrial applications, from medical to aerospace, including metallurgy and surface treatment. This article offers an overview of this discreet but very real revolution.
At the Heart of Matter: What is Plasma?
Often referred to as the "fourth state of matter," plasma is an ionized gas in which some atoms or molecules have lost some of their electrons, creating a mixture of positive ions and free electrons. This composition gives plasma a fundamental property: electrical conductivity. Contrary to popular belief, not all plasmas are extremely hot. We actually distinguish two main families:
Thermal Plasma
Where electrons and ions are at roughly the same temperature (several thousand degrees). It is used in plasma torches for cutting, welding, or waste treatment.
Non-Thermal Plasma (Cold)
Where only the temperature of electrons is high, while ions and gas remain close to ambient temperature. This extraordinary characteristic allows it to be used on sensitive materials, even on biological tissues.
It is this latter category that is experiencing the most remarkable growth, with a global market expected to grow from $2.92 billion in 2024 to $11.14 billion by 2034, according to projections 5 .
The Multiple Faces of Plasma in Industry
Revolution in Medicine and Biology
Cold plasma is operating a silent revolution in the field of health. Its applications are multiple and particularly promising in two key areas:
- Wound care and dermatology: Cold plasma can sterilize chronic wounds while stimulating tissue regeneration. This segment alone accounts for 46% of the cold plasma market 5 .
- Sterilization of medical devices: Facing 136 million nosocomial infections annually worldwide 5 , plasma offers a non-chemical alternative for decontaminating surgical instruments and surfaces.
A meta-analysis published in Nature in April 2025 even demonstrated that the combination of cold plasma with chemotherapy enhanced antitumor effects against melanoma, opening exciting perspectives in oncology 5 .
Medical Plasma Applications
Wound care represents 46% of cold plasma market
Medical device sterilization: 25% market share
Oncology applications: 15% and growing
Powder Treatment and Metallurgy
In the field of metal powders, crucial for additive manufacturing (3D printing), plasma brings decisive added value. The plasma powders market, valued at $1.5 billion in 2024 and projected to reach $2.8 billion by 2033 4 , testifies to this growth.
Plasma processes, notably plasma atomization and plasma spheroidization, allow the production of metal powders with exceptional purity and sphericity, with improved mechanical properties. These characteristics are decisive for demanding sectors such as aerospace, medical (implants), and automotive 4 .
Plasma Powder Market Growth
Projected growth of plasma powder market (2024-2033)
Surface Treatments
Plasma is also transforming our approach to surface treatments. In the polymer and plastics industry, it advantageously replaces traditional chemical treatments to modify surface tension and improve the adhesion of inks, paints, or adhesives 2 .
The plasma thermal spray process allows the deposition of extremely wear-resistant, corrosion-resistant, or high-temperature resistant ceramic or metallic coatings on critical parts for the energy and aeronautical sectors 4 .
Electronics and Semiconductors
The remote plasma sources (RPS) market, essential for semiconductor manufacturing, is expected to reach $4.65 billion by 2034 7 . These technologies allow cleaning, etching, and thin-film deposition operations with unmatched precision.
Industrial Applications of Plasma by Sector
| Industrial Sector | Main Application | Key Advantage |
|---|---|---|
| Medical | Device sterilization | Non-thermal alternative without chemical residue |
| Agri-food | Surface and packaging decontamination | Reduction of contaminants without product alteration |
| Aerospace | Protective coatings on critical parts | Increased resistance to wear and corrosion |
| Automotive | Surface treatment before bonding | Improved adhesion without abrasives |
| Electronics | Semiconductor wafer cleaning | Nanometer precision and absence of damage |
Focus: A Concrete Experiment - Improving Seed Germination with Cold Plasma
Context and Methodology
A fascinating application of cold plasma is found in the agricultural field, where researchers have explored its potential to improve crop germination. A recent study focused on treating soybean seeds using cold plasma technology 2 .
Experimental Protocol:
Sample Preparation
Soybean seeds of identical variety are divided into two batches - an untreated control group and an experimental group.
Plasma Configuration
A cold plasma generator at atmospheric pressure is used, with an argon and air gas mixture.
Treatment
Seeds in the experimental group are exposed to cold plasma according to controlled parameters (distance, duration, power).
Measurements
Both groups are then germinated under identical conditions, with daily monitoring of germination rate and seedling vigor.
Results and Analysis
The results obtained are significant: plasma-treated seeds showed a 14.66% increase in germination rate compared to the control group 2 .
This benefit is explained by several mechanisms activated by plasma:
- Modification of seed coat permeability: Plasma treatment causes micro-erosion of the outer layer of the seed, facilitating water absorption and thus accelerating the germination process.
- Biochemical activation: Plasma generates reactive oxygen and nitrogen species that act as molecular signals, stimulating enzymatic activity and embryonic metabolism.
- Surface decontamination: Treatment reduces the microbial load on the seed surface, limiting disease risks during germination.
Impact of Plasma Treatment on Soybean Germination
| Group | Germination Rate (%) | Average Germination Time (days) | Germination Vigor (index) |
|---|---|---|---|
| Control | 82.3 | 3.2 | 4.1 |
| Plasma Treated | 94.4 | 2.5 | 5.8 |
The Scientist's Toolkit: Tools of the Plasma Revolution
The development of plasma applications relies on specialized instrumentation and high-tech materials. Here are the main tools that equip laboratories and production lines:
Atmospheric Cold Plasma Generators
These devices, often in the form of portable plasma jets, produce stable cold plasma in open air, ideal for treating sensitive or biological surfaces.
52% of medical marketDielectric Barrier Discharge (DBD) Reactors
Composed of electrodes separated by a dielectric, they generate uniform cold plasma over large surfaces.
Fastest growing technologyInductively Coupled Plasma (ICP) Systems
Dominating the semiconductor market (50% share), these sources produce high-density plasma for nanoscale precision etching and deposition.
50% market shareMicrowave Plasma Sources
In rapid growth, they offer exceptional stability and purity for critical applications in electronics and photonics.
Rapid growth segmentAdvanced Materials for Components
Tungsten and its alloys, advanced steels, and low atomic number materials are essential for components facing plasma in nuclear fusion applications.
Extreme conditionsMarket Distribution
Future Perspectives: Artificial Intelligence and Nuclear Fusion
Artificial Intelligence
Artificial intelligence is beginning to play a key role in optimizing plasma processes. Machine learning algorithms now enable real-time control of plasma generation parameters, suppressing instabilities and allowing unprecedented fine-tuning.
In the medical field, AI facilitates the personalization of treatments, while in semiconductors, it enables predictive maintenance of equipment 7 .
Nuclear Fusion Research
Nuclear fusion research, although more prospective, represents an exciting horizon for plasma technologies. Facilities like DIII-D in the United States or ITER in France are pushing the boundaries of our mastery of magnetically confined hot plasmas.
These works advance thanks to global collaboration and in turn nourish the entire industrial sector through the innovations they generate in materials resistant to extreme conditions, superconductors, or diagnostic systems 8 1 .
Conclusion
From sterilizing chronic wounds to producing ultra-pure metal powders, to manufacturing our smartphones, plasma has established itself as an indispensable industrial tool. This "fourth state of matter," once confined to astrophysical phenomena, has become the precious ally of technological innovation. While the market is experiencing double-digit growth and research is advancing at a sustained pace, one certainty emerges: plasma, in all its forms and at all its temperatures, will continue to push the boundaries of what is possible in the coming decades, offering elegant and sustainable solutions to the industrial and societal challenges of our time.
