Patent ID: 8550028

Claim:
A system, comprising: a spray device; at least two pairs of rollers located about the spray device, each of the at least two pairs of rollers located orthogonal to one another, between the spray device and a surface to be coated by the spray device, each of the at least two pairs of rollers are located in a raw spray stream generated from the spray device, each of the at least two pairs of rollers are configured to shape the raw spray stream generated from the spray device to a shape-defined spray stream that coats the surface; at least two pairs of thermal spray foil supply spools, each pair of thermal spray foil supply spools configured to supply thermal spray foil to one pair of the at least two pairs of rollers, wherein the thermal spray foil supplied from each pair of thermal spray foil supply spools to the one pair of the at least two pairs of rollers wraps around rollers in the one pair of the at least two pairs of rollers without passing directly through a path of a portion of the raw spray stream that is shaped by the one pair of the at least two pairs of rollers to form the shape-defined spray stream that coats the surface; at least two pairs of take-up spools, each pair of take-up spools configured to receive the thermal spray foil after passing through one of the at least two pairs of rollers; and at least two pairs of guide pulleys, each pair of guide pulleys configured to guide the thermal spray foil from one of the at least two pairs of rollers to one of the pairs of take-up spools operating therewith.