In this study, a numerical investigation has been performed on the spreading and solidification of a coating material droplet onto the rigid substrate in the thermal spray process. The computational model is validated through the comparison of the predicted numerical result and the experimental data for flat substrate. An analysis of the deposition formation on a substrate with small concentric grooves or ridges was performed. To examine the characteristic of the impact and solidification of a liquid droplet on the substrate with concentric grooves or ridges, a parametric study was conducted with various shapes and sizes of concentric grooves or ridges.