The present study aims to establish the potential of producing various hard metal industrial thick components using the High Velocity Oxy-Fuel (HVOF) thermal spray process, rather than by sintering or casting techniques currently used. It is innovative in that generally research work earned out on this process focuses on coating technologies. In order to spray-form thick tungsten carbide cobalt (WC-Co) components, certain problems have to be overcome. More specifically these problems include minimizing residual stresses (which cause shape distortion in the components), therefore maintaining the integrity of the deposit on a microstructural scale. Residual stress arises during deposition and, in the present research, was reduced by limiting the rise and fluctuation of the deposition temperature. This was achieved by the utilization of a carbon dioxide cooling system and automated traverse movement of the spray gun, which together enabled continuous deposition at a steady temperature of 500°C, reducing the residual stress by 58% compared to manual spraying. A spraying distance of 200mm and a powder feed rate of 38gmm 1 exhibited the lowest stress within the deposit using the automated system. The minimization of the residual stress increased the maximum deposit thickness achieved from 0 6mm to 1 2mm. Higher deposit thicknesses were achieved when the deposition area was reduced. These findings were simulated by the finite element analysis technique The present research describes the successful production of 9mm thick spray-formed WC-Co components (12mm m diameter) Associative work in this thesis includes the fabricating of larger more complex shaped components, tensile specimens. The tensile specimens were used to measure the stiffness of the deposit (substrate free) and a Young’s modulus of 189GPa was measured Post-heat treatment and measurement of Vicker’s hardness and porosity were also investigated. Finally, the economic feasibility of producing WC-Co cylindrical components using spray-forming is briefly discussed.