Several attempts have been made in the past to compare the coating costs associated with different processes. These have been based normally on various process related assumptions. The comparisons have typically been biased by the views and objectives of the presenters. A realistic comparison of the process costs needs to be based on the actual production methods and the historical data. This paper presents the comparisons of the Vacuum Plasma process with two versions of the HVOF process. Both small and large part geometries are considered as well as part complexity. The cost data will be presented as an actual cost per part to coat, including both operating costs and amortized capital costs. This method is preferred over the theoretical calculation of the cost per pound of material sprayed. The latter method requires a number of assumptions and does not consider the limitations of production cycles and material handling.