Advances in thermal spraying are occurring in two general directions. On the one hand, spray processes are becoming colder, facilitating the production of oxide-free coatings in air atmospheres. On the other hand, new systems are being developed that enable higher powder throughput, thus making production faster and more efficient. In order to lock in these time-saving advantages, more and more applications are using CO2 as a cooling medium to increase cooling efficiency and optimize spraying processes. This paper provides an overview of the use of CO2 and its suitability for new applications.