Abstract: A powder coating booth comprising a pair of identical polycarbonate shells disposed opposite each other to define a coating chamber having smooth, curvilinear internal surfaces to facilitate the recovery and recycle of excess coating powder. Narrowed down end openings are provided to help confine the excess powder. A thermoplastic material such as polyvinyl carbonate or polycarbonate is formed in a large thermoforming machine with vacuum and pressure to fabricate the components of the coating chamber, which may be up to ten feet wide, ten feet tall, and thirty feet long or longer.