A method of and apparatus for spraying a molten thermoplastic polymer composition onto a substrate. The thermal spray apparatus of the present invention includes a source of pressurized molten polymer material, a source of pressurized hot gas, and a spray head which is in fluid communication with the source of pressurized molten polymer material and a source of pressurized hot gas. The pressurized hot gas forms a flowstream as it exits the spray head and acts to atomize and transport the molten polymer material, in a molten state, to the substrate so that the substrate is coated. The molten polymer is atomized into relatively uniform particulates of molten plastic which aids in applying a uniform coating to the subject substrate. It is emphasized that this abstract is provided to comply with the rules requiring an abstract which will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. 37 C.F.R. § 1.72(b).