The objective of this study is to investigate the feasibility of high velocity oxy-fuel (HVOF) spraying of tool steel coating containing high boron and high carbon. A full factorial experimental design was established to investigate the influence of process parameters on the coating formation. The microstructural investigations revealed that the tool steel containing ultrahigh boron and high carbon can be coated using HVOF. The coating microstructure does not seem to be conventional lamellar structure and consists of high density micro-cracks. However, the coating features superior hardness of about 980 HV and shows the potential for wear resistance applications.