Research so far has revealed that in friction surfacing the mechatrode force (F), mechatrode rotation speed (N) and substrate traverse speed (Vx) are of critical importance for the final quality of the coating and bond. In the present study, three state variables that reflect coating quality were considered as a subject for optimisation and in this context a target for process parameter selection. These are coating thickness (Ct), coating width (Cw). The optimisation procedure considered in this study involved. Development of a methodology for in-process precision measurement of axial load, traverse speed and rotational speed. Development of an empirical model involving process parameters of coating quality state variables i.e coating thickness and coating width. The friction surfacing machine consists of a power rotor which can move vertically with high precision Z. Under the rotor there is an XY table, which can be positioned and moved accurately. The system is controlled using a serial computer link. The input parameters to the machine being: Spindle rotation speed Spindle direction Table movement