Thermoplastic polyvinyl chloride (PVC) is one of the most widely used polymers in the world. Due to its versatile nature, PVC is used extensively across a broad range of industrial, technical and everyday applications including widespread use in building, transport, packaging, electrical/electronic and healthcare applications. In this study, thermal spray technology was used to apply PVC powder on metal substrate. It was revealed that the spray parameters such as working distance, preheat and flame temperature played the important role on the properties of PVC coating.