Developing a good cold spray repair is a not a trivial task. We take into consideration a broad range of factors including loading levels, wear and corrosion, and accessibility. First we examine basic feasibility, including likely materials and access issues (i.e. is the location sprayable?). Design data is also needed at this point to establish the properties needed for the cold spray deposition. If design data is not available, the part must be reverse engineered. Next, we select an appropriate material. If no data exists for an appropriate material, then some initial feasibility is needed to see if reasonable properties are achievable. Finally, mock-ups or a first article are prepared and evaluated. If all tests pass, a cold spray process specification is written for the application.