Thermal spray R&D, spanning fundamental analysis of splat development to industrial applications of innovative titanium coatings, is a core focus of research at three of New Zealand’s leading universities.  Fundamental analysis focuses on the effect of surface chemistry on splat formation, innovative heat treated carbide coatings and polymer composite coatings.  Industrial links have generated innovative titanium alloy coatings based on world leading low-cost titanium powder production technology developed in NZ.  Strong ties to the light metals industry have initiated innovative developments aimed at extending the wear and corrosion functionality of titanium, aluminium and magnesium alloys through the use of thermal spray technology.