Abstract: The plasma spray method produces a material deposit on a substrate to form either a protective coating of a near net shape body, or produces a powder of a given material. The material is supplied to a plasma discharge in the form of a suspension comprising small solid particles of that material dispersed into a liquid or semi-liquid carrier substance. The suspension is brought into the plasma discharge by an atomizing probe using a pressurized gas to shear the suspension and thus atomize it into a stream of fine droplets. The plasma discharge vaporizes the carrier substance and agglomerate the small solid particles into partially or totally melted drops which are accelerated to hit the substrate and form thereon the coating or near net shape body. Alternatively, the molten drops can be solidified in-flight and collected into a vessel to produce a powder of that material.