Experimental studies of the subsonic combustion process have been conducted in order to determine the quality and economics of polyester, epoxy, urethane, and hybrid polyester-epoxy coatings. Thermally sprayed polymer coatings are of interest to several industries for anti-corrosion applications, including the infrastructural, chemical, automotive, and aircraft industries. Classical experiments were conducted, from which a substantial range of thermal processing conditions and their effect on the resultant coating were obtained. The coatings were characterized and evaluated by a number of techniques, including Knoop microhardness tests, optical metallography, image analysis, and bond strength. Characterization of the coatings yielded thickness, bond strength, hardness, and porosity.