Thermal spraying processes are well known in the industry for providing relatively dense components. The Gas Dynamic Spray (GDS) technologies are a growing alternative, especially after the great success of certain applications such as plasma and thermal spray formed components.  One of the advantages of the GDS is the possibility to obtain complex thin-walled shapes of various powder materials and composites. The optional post-spraying processes such as sintering, sizing and little machining may be applied. Using the low pressure radial injection GDS method, some new thin wall components have been formed. The process involves the automatic mechanical removal of sprayed ring components from a mould. Both the structure and properties of powdered material along with the GDS technology itself were studied. The main spraying and mould parameters were found to achieve high durability of moulds, which allowed the realization of a large scale GDS forming technology.