A thermal spray system may include a thermal spray torch configured to produce an emission of material, at least one camera configured to capture an image of the emission of material emitted by the thermal spray torch, a diagnostic device communicatively coupled to the at least one camera, and a controller communicatively coupled to the diagnostic device. The camera may be configured to transmit an image of the emission of material to a diagnostic device that may be configured to determine a characteristic of the emission of material based on the image. The diagnostic device may transmit the characteristic to a controller that may control a position of the thermal spray torch based on the characteristic.