Although based on thermal spray concepts, the cold gas dynamic spray (CGDS) eliminates the use of high-temperature and materials not melted in the coating process, which eliminates phase changes or the formation of oxides and results in a pure and dense coating layer. The system is capable of applying a number of powder coating materials, including aluminum, aluminum composites, copper, superalloys, silver and titanium. The coatings can be applied to any metallic and many nonmetallic substrates.