This paper first presents some typical results that illustrate the need for closed-loop stabilization of plasma spraying processes. A strategy to identify the most efficient control actuators is then explained, followed by a description of a robust operator closed-loop feedback method. This method can be directly implemented on current commercial sensors and applied to older spraying equipment than cannot easily be interfaced to modern computers. The method is also capable of implementing tight computer-controlled closed-loop feedback on more modern equipment. A discussion of minimum sensor requirements is also given.