Thermal spray is a widespread technology on the way to large scale production. Driven by industrial importance, companies of all sizes employ this technology, with research mainly driven to improve quality and reduce cost. In order to produce high-quality coatings, efforts have been made to provide on-line process control. To find out which parameters affect coating formation and thus which of these parameters should be monitored high level cost intensive diagnostic systems have to be used. This work introduces selected diagnostic systems for the on-line process control under the condition of serial production: shadow imaging for the particles (PSI), a system to measure particle velocities (PVI) and an integral working system using a qualitatively image algorithm (PFI).

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