There has been much published with regard to personal protective equipment (PPE) and its use for thermal spray processes. A survey of literature, articles, and guidelines leads one to believe that there is not a common understanding of the principles and regulations behind the use of PPE, at least as it relates to thermal spraying. This paper will attempt to clarify some of the misconceptions and regulations regarding PPE as it relates to thermal spraying. PPE for hearing, sight, and respiration will be covered with specific attention to the unique problems associated with plasmas, arcs, and flames. An update on the rapidly changing regulations regarding occupational exposure hexavalent chromium will also be given.