U.S. Industrial Automation and Control Systems Market to Reach USD 87.5 Billion by 2030, Driven by Industry 4.0 Transformation

The U.S. industrial automation and control systems (IACS) market, valued at USD 47.04 billion in 2024, is projected to grow at a CAGR of 10.6% from 2025 to 2030, reaching an estimated USD 87.5 billion by 2030, according to DataM Intelligence. The fastest growth is attributed to rising Industry 4.0 adoption, increasing labor shortages, and the demand for operational efficiency across manufacturing, healthcare, and energy sectors. Automation is reshaping the U.S. industrial landscape-integrating artificial intelligence (AI), IoT, and robotics into workflows to enhance safety, optimize productivity, and reduce costs.

The progression toward smart factories and digital twins-combined with cloud computing, edge processing, and 5G connectivity-continues to revolutionize industrial automation. Predictive maintenance, AI-driven analytics, and IIoT-enabled control systems are allowing companies to conduct remote diagnostics and optimize operations in real time. The U.S. position as a leader in AI integration, coupled with strong investments from industrial giants such as Siemens, ABB, and Schneider Electric, underpins the growth of the automation ecosystem.

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Key Highlights from the Report

➤ U.S. industrial automation and control systems market expected to reach USD 87.5 billion by 2030 at a CAGR of 10.6%.
➤ Control valves segment led the market in 2024 with over 25% share due to advanced flow control applications in process industries.
➤ Industrial robots expected to grow at 12.6% CAGR through 2030, driven by adoption in automotive and consumer electronics sectors.
➤ Distributed Control Systems (DCS) dominated 2024, with widespread use in oil & gas, power, and chemicals.
➤ Manufacturing sector accounted for the largest market share, supported by Industry 4.0 investments and predictive analytics integration.
➤ Healthcare automation segment to record the fastest CAGR through 2030 due to precision and efficiency needs in patient care.

Market Segmentation

By Component Type:

The control valves segment accounted for over 25% of revenue in 2024, supported by rising demand for efficient flow control in industries such as oil & gas, chemicals, and power generation. The introduction of smart IoT-enabled valves ensures real-time monitoring and predictive maintenance-reducing energy waste and downtime. The industrial robot segment, anticipated to grow at 12.6% CAGR, is benefiting from high adoption in precision-oriented manufacturing and electronics assembly. Enhanced human-robot collaboration and flexibility have made robots more accessible for small and mid-sized manufacturers.

By Control System:

The Distributed Control System (DCS) segment dominated in 2024 and will continue to lead due to its resiliency in managing complex, continuous industrial processes. DCS platforms, integrated with AI and IIoT capabilities, are essential in maintaining safe and efficient operations. Meanwhile, the Supervisory Control and Data Acquisition (SCADA) system segment is expected to grow rapidly, driven by Industry 4.0 applications requiring real-time data visualization, remote control, and predictive decision-making across utilities and manufacturing plants.

By Vertical:

The manufacturing sector accounted for the largest share in 2024. Widespread industrial automation implementation in automotive, aerospace, and food manufacturing has driven demand for next-generation control architectures. Meanwhile, the healthcare sector is set to record the highest growth rate through 2030 as hospitals and laboratories automate workflows-spanning drug manufacturing, robotic surgeries, diagnostics, and inventory management-to improve precision and operational efficiency.

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Regional Insights

The United States remains the largest market for industrial automation and control systems in North America. Growth is supported by widespread digital adoption, 5G infrastructure rollout, and government-backed initiatives promoting advanced manufacturing. States such as Texas, Michigan, and California continue to serve as industrial innovation hubs. In addition, the presence of technology leaders like Rockwell Automation and Honeywell International accelerates automation integration across diverse sectors.

Ongoing investments also reinforce U.S. competitiveness in global automation. For instance, Siemens announced a USD 10 billion investment in manufacturing and AI infrastructure, while ABB Ltd. committed USD 120 billion to expand its production capacity for automation components. Schneider Electric's Energy Innovation Center in Houston further strengthens the nation's foundation for sustainable, digitally connected industrial solutions.

Market Dynamics

Market Drivers:

The continued evolution of Industry 4.0 and integration of digital twin technologies are transforming industrial productivity. The deployment of autonomous robots, machine vision, and AI-powered systems enhances data transparency, predictive planning, and plant efficiency across critical sectors such as energy, oil & gas, and chemicals.

Market Restraints:

High initial investment costs, cybersecurity challenges, and integration complexities remain major barriers. The need for upgraded cybersecurity tools is particularly pressing given the growth in interconnected industrial systems and potential vulnerabilities in cloud-based infrastructure.

Market Opportunities:

Emerging applications in edge computing, autonomous operations, and smart robotics present strong opportunities for innovation. The growing deployment of control and automation systems in renewable energy plants, EV manufacturing, and healthcare will open new growth avenues for technology providers through 2030.

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Reasons to Buy the Report

✔ In-depth analysis of market trends, drivers, and technological advancements transforming U.S. industries.
✔ Comprehensive segmentation covering component type, control system, and industrial verticals.
✔ Strategic insights on future investments and innovation pipelines by key players.
✔ Competitive landscape analysis with focus on M&A, product expansion, and sustainability initiatives.
✔ Actionable recommendations for stakeholders exploring digital transformation opportunities in automation.

Frequently Asked Questions (FAQs)

◆ How Big is the U.S. Industrial Automation and Control Systems Market in 2024?
◆ Who are the Leading Players in the U.S. Industrial Automation Sector?
◆ What is the Projected Growth Rate of the Market from 2025 to 2030?
◆ Which Vertical is Expected to Account for the Largest Market Share by 2030?
◆ How is Industry 4.0 Driving Adoption of Automation Solutions Across the U.S.?

Company Insights

ABB Ltd.

Honeywell International, Inc.

Siemens AG

Schneider Electric Corporation

Emerson Electric Co.

Mitsubishi Electric Corporation

Rockwell Automation, Inc.

Omron Corporation

Yokogawa Electric Corporation

Kawasaki Heavy Industries, Ltd.

Recent Developments:

March 2025: Schneider Electric inaugurated its 10,500-square-foot Energy Innovation Center in Houston, showcasing AI-driven energy management and automation solutions.

March 2025: Siemens AG invested over USD 10 billion in new U.S. manufacturing sites and acquired Altair to expand its AI-driven design software capabilities.

January 2025: ABB Ltd. announced a USD 120 billion expansion for its U.S. operations, including two new manufacturing facilities in Tennessee and Mississippi to boost automation infrastructure capacity.

Conclusion

The U.S. industrial automation and control systems market is entering an accelerated growth phase driven by technological innovation, data connectivity, and the drive for operational resilience. Advanced automation and AI-powered technologies are redefining manufacturing, energy, and healthcare operations, enabling higher precision and reduced costs. Major investments by industry leaders, coupled with the expansion of 5G and IIoT ecosystems, are enhancing productivity nationwide. As the U.S. transitions toward smart and sustainable industrial infrastructure, automation and control systems remain the backbone of this digital transformation.

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This release was published on openPR.