The suspension plasma spraying (SPS) technique implemented on DC plasma spray guns is a complex thermal spraying process. In order to gain a better understanding of this deposition technique a systematic “splat” study using a shutter mechanism and the line-scan test was conducted varying liquid feedstock properties (viscosity and surface tension) and injection parameters (stream velocity and mass-loading). Splat morphology revealed the degree of particle agglomeration within the droplet formed from the liquid/plasma interaction, as well as their impacting velocity and heating history. The droplet formation was correlated to the liquid feedstock injection velocity and its viscosity. A simple model was developed to explain the experimental results correlating suspension properties to suspension droplet fragmentation mechanism.