Suspension plasma spraying is a promising modification to traditional plasma spray techniques that may allow plasma sprayed layers with finer microstructures and better porosity control to be produced.  The fine microstructures and controlled porosity of these layers combined with plasma spraying’s ability to produce layers rapidly without requiring a post-deposition heat treatment makes this an interesting new manufacturing method to produce solid oxide fuel cell (SOFC) active layers.  This study uses an axial injection suspension plasma spray system to produce thin, dense layers of fully stabilized yttria-stabilized zirconia (YSZ) for use as an SOFC electrolyte.  A systematic study was performed to investigate the effect of varying a number of different feedstock, plasma, and other spray parameters on the resulting coating properties.