Plasma spraying has been used extensively in industry because of its high deposition rate, capability of coating complex shapes, and the ability to process high melting temperature materials. Because of the high melting temperature of rare earth oxides (over 2000 °C), plasma spray is an ideal candidate to fabricate REO superhydrophobic coatings. Conventional plasma spray uses powder with particle sizes ranging from 10 micron to 100 micron as the feedstock. The powder is entrained in a gas stream and injected into the plasma plume. Decreasing the particle size could potentially lead to nano-scale microstructures in the coating, which enhances coating properties such as strength, toughness and wetting behaviors.