Thermal spray involves melting metal and spraying it onto a surface to form a coating. The thermal spray fumes are airborne. They are micron size and dangerous. The metal dust particles generated during the thermal spray process usually enter the respiratory system, but they can also irritate the eyes, mouth, throat, stomach and skin. Workers involved in thermal spray processes face serious risks if they are not protected. Dust collectors are the preferred engineering control to keep operators from serious health concerns. Dust collectors must also be fitted with the correct explosion protection equipment…explosion vents, flame retardant cartridges, and possibly spark traps.