For 20 years now, the HVOF-method has been an industrially-established process for the application of hard-metal coatings to prevent wear phenomena from happening. A successful application combines the typical process parameters, conditions of materials and, above all, constructive frame conditions. In the following, we will present investigations for coating uneven outlines/contours such as edges, cavities or uneven surfaces. Furthermore, constructive frame conditions will be deduced from these and compared to our practical experience. The distribution of the layer thickness and its accessibility with the spray jet will be discussed as well. Here, we will have a closer look on which mechanical properties the basic substance has regarding hardness

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