Milled particles from a (SiO2-CaO-Fe2O3) glass were smoothed by flame spraying, focusing on the elimination of superficial roughness or angularity without reaching complete fusion of the glass. The purpose of this study is the further application to glass ceramic microspheres where avoiding thermal resetting of the second phase is needed. Finite element modeling of the thermal and kinematical history of glass particles throughout the flame was performed in order to predict the suitable size range of injected particles. Crushed and sieved glass powders were sprayed into oxyacetylenic flame and characterized by SEM, showing the importance of the diameter and anisotropic morphology of angular feedstock when discriminating between superficial smoothing and complete fusion in the glass.