One of the greatest shortcomings of conventional plasmas is the arc instability leading to inconsistent processing of the powder particles. This results in poor coating quality and low deposit efficiencies. Being able to take advantage of molecular gases with higher enthalpy, using a thermally dynamic plasma jet and without the detrimental effect on gun hardware, means much lower costs per kilogram of material deposited. The 100HE High-Enthalpy plasma spray technology is designed to operate with ternary gas mixtures and this results in higher spray rates, higher deposit efficiencies and better coating quality. This paper focuses on an innovative modern plasma spray process. The application rate and the application efficiency could be increased significantly with an axial, also with a radial, powder injection. The coatings produced with 100HE for wear and corrosion protection and thermal insulation are presented and discussed. Paper includes a German-language abstract.