The Coatings and Surface Engineering group at the University of Nottingham has led research in advanced material development and thermal sprayed coatings for seven years. They frequently use cold spray, APS and HVOF processes to develop new and advanced materials. They realized a need for monitoring spray processes to relate process parameters to material theory and deepen their understanding. They have been using the Accuraspray 4.0 for three years to perform parameter selection, relate parameters to coating microstructure and streamline new processes.