Deposition techniques have been advanced to the extent that it is now becoming an important process to improve mechanical properties of the surface of the material by depositing composite powder particles. However, choosing an efficient and versatile procedure to coat thin films will be difficult and scaling that procedure to our requirements is also an important factor to be considered. In this work, the Electrostatic Spray Deposition system has been used which uses electrostatic forces to deposit powder particles onto the grounded substrate. This method offers advantages such as simple setup, low operational cost, minimal material waste, can be applied to complex geometries, and is scalable, making it suitable for protective coatings in biomedical, automotive, and paint industries applications. The ESD chamber has been designed and analyzed to ensure that it meets the requirements under operating conditions. Then the system was fabricated and tested using powder particles onto a substrate and the results demonstrate ESD’s capability for achieving moderately uniform coatings. Apart from these, laser sintering and furnace sintering have been performed using ESD coated substrates to understand ESD coatings.