Abstract The practical experience with the new Castolin Eutectic CJK5 High Velocity Oxy Fuel thermal spray unit has grown since its successful launch in 2011. It has many design features that simplify the user interface and servicing, but maintaining outstanding coating quality. The technical and practical features are described with detailed microstructural characterization of the resulting carbide based coatings using an established powder composition from several powder sources. With the recent development of a state-of-the-art metal powder manufacturing plant in Europe, highest quality “satellite-free” metal powders can be manufactured. New self-fluxing chemistries have been developed that are also low in Nickel and are designed to have good wear resistant properties. With the growing practical experience and parameter optimization, several innovative powders and coatings have been developed and are presented. Microstructural and mechanical properties and their relationship to processing parameters are presented.