Abstract: A plasma spray process used for coating surfaces of a variety of components made of a plastic substrate. Powder particles are injected into a plasma jet where they soften and then strike the surface at high velocity to produce a strongly adherent coating. The component or work piece the coating is being applied to remains cool because the plasma is localized at the plasma gun. The plasma spray process allows for the melting of glass particles, creating a transfer mechanism to the plastic substrate. Components having complex shapes can be coated, without the issues currently encountered in dip coating. The powder coating is applied via plasma spraying, as a protective layer, giving glass like surface properties to a component having complex molded or formed shapes.