Stabilised ZrO2 particle in flight characteristics in an Ar-H2 atmospheric plasma jet have been studied using analytical and experimental techniques. A commercial code was used to simulate the plasma flow. A standard k-ε turbulence model was used. Powder particle velocity, temperature history and trajectory were calculated using a stochastic discrete particle model and compared with measurements. A good correlation was found between predictions and measurements. Relationships between the sprayed particle velocity, temperature and size were investigated and a clear correlation was found. The method presented here seems to be a powerful and cost-effective tool, which could be used to optimise spray parameters off-line.