Thermal spraying of fine and ultrafine powders is realised by a novel method based on highly filled filaments as feedstock material for high velocity oxy fuel flame spraying (HVOF). Hereby, the desired coating material is supplied as finely dispersed powder within a polymer filament. Thus, the polymer works only as a transport medium and is fully decomposed when entering the combustion zone instantly releasing the solid dispersion, similar to the liquid dispersion medium in a suspension. It can work as an appropriate method to process fine and ultrafine powders. The solid nature of the dispersion medium poses several benefits compared to liquids, especially from the manufacturing point of view, since the process is geared to a wire flame spraying method. This work focusses on the challenges and benefits of this novel approach. First experimental results of spraying different filaments are presented.