Coatings manufactured via thermal spray typically have porosity in them. One of the most common processes for characterizing a spray coating is metallographic preparation. However, it’s long been established that there can be problems in both finding a correct approach to preparation, and to reproducing this approach over time. A good method is only part of the story! This paper looks at the metallographic preparation process in sufficient detail to characterize the importance of each stage as well as the application methods.