Abstract The Axial III, launched in 1994, is a patented plasma spray torch with axial injection of feedstock. In comparison to the traditional radial injection, axial injection technology has proven to offer greater deposition efficiency, throughput, and cost savings on numerous applications . Despite these benefits, the original Axial III M600 torch had several limitations due to its size, mass, and number of components. To address these shortcomings, a smaller, lighter, and more ergonomic version of the torch was developed, called the Axial III Plus, that produces the same high-quality coatings at high feed rates and deposition efficiency. This paper highlights the innovations in this new torch and the potential applications it opens for the plasma spraying industry.