Developing and using efficient controls for thermal spray processes is essential to produce coatings in a more consistent manner day after day. This paper discussed the different approaches that can be used, today or in the future, to better control spray processes. The various steps or sub-processes involved in thermal spraying are first reviewed identifying the key parameters that can be monitored and controlled. An overview of current sensing techniques and those under development for probing the state of these key parameters will then be presented. Finally, different control approaches will be reviewed looking at the basic knowledge and models required to implement an efficient and intelligent control strategy for thermal spray processes.