Thermal spray assembly and method for using it

A thermal spray assembly for transforming precursor material into a layer of deposited material joined to a substrate body;

• comprising:
• a plasma torch for producing a plasma jet from a plasma nozzle and a feeder mechanism for guiding the precursor material into the plasma jet in use and being capable of providing a feeder orifice when in an open condition;
• the feeder mechanism comprising
• a distribution chamber configured for guiding moving precursor material azimuthally around the plasma torch,
• a plurality of deflector structures configured for deflecting the precursor material from the distribution chamber and guiding it into
• a guide chamber, the guide chamber configured for guiding the precursor material to the plasma jet in use, wherein the deflector structures comprise projections spaced apart from each other and extending from the distribution chamber to the guide chamber.