The influence of solvent type on splat formation and coating microstructure using the Solution Precursor Plasma Spray process was studied. Droplet with a high surface tension and high boiling point solvent experiences incomplete solvent evaporation process in the plasma jet leading to a porous coating. Droplet created from a low surface tension and low boiling point solvent undergoes rapid solvent evaporation, solute precipitation, pyrolysis, melting process in the plasma jet and forms splat upon impacting on the substrate; the build-up of splats results in a dense coating.