Abstract The quality of thermally sprayed layers is largely determined by the quality of the spray additives used. A novel, simple and inexpensive test method based on fully automated image analysis in combination with a conventional, high-resolution slide scanner instead of a transmitted light or electron microscope for object detection offers an interesting alternative. This process is easy to use and provides information on grain size distribution and shape within a few minutes. The aim of this paper is to compare this novel test technology with test methods established and standardized in everyday spraying technology, such as sieve analysis, according to ISO 4497 or powder particle size determination, using laser scattered light methods. Paper includes a German-language abstract.