Abstract This article examines the splat shape at off-normal angles in plasma spray and investigates the relationship between the splat elongation ratio and the spray angle on various spray materials and particle sizes. The applicability of the model to the experimental results is investigated. In this study, six powders of aluminum, copper, and nickel as metal spray materials and of alumina, titania, and zirconia as oxide materials were sprayed. It was observed that the model agreed well with the elongation ratio of the experimental results in the range between 90 and 30 degree. The model values were over-estimated than the practical results at spray angles less than 15 degree.