This paper discusses a research project with the goal of homogenizing the properties of three-cathode plasma sprayed coatings through the use of advanced diagnostics and numerical simulations. The approach included the development of a suspension injection setup, the determination of plasma and suspension behavior through diagnostic methods such as computer tomography and particle image velocimetry, and the analysis of coating formation through computational fluid dynamics and finite element analysis. The results of their investigations are presented, including tomographic reconstructions of temperature distribution, suspension behavior measurements, and coating analysis. The paper concludes with a discussion of the future directions of their research and the potential impact on the field of thermal spray coatings.