The report includes an in-depth analysis of the U.S. Industrial Automation and Control Systems Market, including market size and trends, product mix, Applications, and supplier analysis. The estimated size of the U.S. industrial automation and control systems market was USD 48.24 billion in 2024, with a projected growth rate of 10.82% CAGR from 2025 to 2034. The market's expansion is primarily fueled by the increasing demand for improved operational efficiency. As Industry 4.0 continues to evolve, manufacturers are prioritizing the development of smart factories that utilize data analytics, artificial intelligence, and the Internet of Things to enhance machine performance, minimize downtime, and optimize production.

The control valves segment had the largest revenue share in 2024, primarily due to the rising need for precise flow control in various industrial processes. Control valves are crucial for managing the flow of liquids, gases, and steam in industries like chemicals, oil and gas, and water treatment. As industries aim to optimize operations and enhance efficiency, control valves help in regulating processes, minimizing waste, and maintaining system stability. Advances in valve technology, including smart valves connected to the Internet of Things (IoT) for real-time monitoring, are further driving growth in this segment.

The Distributed Control System (DCS) segment accounted for a significant revenue share in 2024 due to its broad application in industries demanding reliable and efficient management of complex processes. DCS systems are vital in sectors like oil and gas and power generation, where constant monitoring and precise control are essential for safety and efficiency. Growing demands for automation and the incorporation of Industrial Internet of Things (IIoT) technologies are expected to sustain growth in the DCS market. Meanwhile, the Supervisory Control and Data Acquisition (SCADA) segment is projected to have the highest growth rate from 2025 to 2034, driven by the adoption of Industry 4.0 and the need for real-time monitoring across industries. SCADA systems are key in energy and manufacturing, allowing centralized management and quick data-driven decisions.

The manufacturing segment had the largest market share in 2024, driven by the rise of Industry 4.0 technologies like robotics, AI, and IoT-based control systems. These advancements help manufacturers optimize production, increase efficiency, and cut labor costs while ensuring output quality. Improved networking and real-time data analytics also support predictive maintenance and streamline operations, tackling issues like high labor costs and shortages of skilled workers. Meanwhile, the healthcare sector is expected to grow the fastest from 2025 to 2034, as automation enhances patient care, reduces inefficiencies, and improves treatment accuracy, with a rising demand for better healthcare and data-driven decision-making.

The Midwest region often dominates market share. This supremacy is widely linked to the region's robust manufacturing base, notably in industries such as automotive, machinery, and equipment production, which are early adopters of industrial automation technologies. Furthermore, the South area is frequently cited as the fastest-growing segment, thanks to increased manufacturing investments, favourable business environments, and an increasing presence of industrial entities.

Key players in this market include ABB Ltd and Honeywell International, Inc. ABB Ltd. is a technology firm that specializes in automation solutions, motion, and electrification, operating through various business segments such as Robotics & Discrete Automation, Motion, Electrification, Industrial Automation, and Corporate. The Industrial Automation segment of ABB provides process and discrete control solutions, advanced process control software, measurement and analytical instrumentation, as well as electric ship propulsion systems.