Powder Flamespray (Combustion Spray) uses a siphon plug arrangement to mix fuel gas of acetylene, propane or hydrogen with oxygen in controlled proportions to provide consistent operation and inhibit backfiring. Powder is injected into the lit fuel gas-oxygen flame where it is melted by the heat of combustion, propelled towards the substrate surface where it quickly solidifies to assimilate the coating. Typical gas stream temperatures are in excess of 3,000°C. A cap at the flame exit that delivers compressed air  and surrounds and appropriately shapes the flame according to the material being processed.

The Powder Flamespray process is similar to the Wire Flamespray process, except that it has the advantage of using powder materials as the coating feedstock, which permits a broader range of coating material options (in particular ceramics).