Abstract: A method for forming a three-dimensional article by thermal spraying utilizes a plurality of masks having a support layer with a removable liner thereon and a cut-away portion. The masks correspond to cross-sections normal to a centerline through the object. A set of masks defines all cross-sections through the object. A first mask is placed above a work surface and sprayed with a deposition material forming a first layer portion of the deposition material within the cut-out and second layer portion on the liner. The liner and second layer portion of deposition material thereon are removed. A second mask is placed over the remaining support portion of the first mask and sprayed with deposition material therein. Then the liner portion of the second mask and deposition material therein are removed. This process is repeated until the three dimensional article is formed. Then the mask support portions surrounding the article are removed from the article.