The original design and materials of the composite “copper-thermal sprayed coating” walls of molds of continuous casting machines have been developed. The walls significantly surpass nickel-plated ones in performance. A comprehensive analysis of the structural-phase state, mechanical and tribological characteristics of the coatings was performed using a specially created test procedure that simulates the actual operating conditions. The research results formed the basis for the creation of an innovative production technology for walls at the Mashprom industrial facilities. The results of the application of the development at the main metallurgical plants of Russia are shown