This paper describes an advanced three-dimensional surface finishing system for quantifying the surface finish of thermally applied cylinder bore coatings. The system can measure surface finish values over the total area of use with and without including the effect of porosity, as well as size distribution and percent area occupied by surface porosity. It can also quantify torn and folded material developed during the honing or grinding process, as well as hone angles in cylinder bores. The system provides a powerful tool for cylinder bore finish development and monitoring the effect of porosity on the finish of plasma coated cylinder surfaces. The paper also discusses the development of replicate material and the comparison of finish values developed through direct imaging and replication. Additionally, it explores the quantification of torn and folded material and crosshatch angles in the cylinder bore finish. Overall, the system improves the quality of finishing data and provides a time-saving solution for production or research and development environments.