Porous composite cathodes containing (La0.8Sr0.2)0.98MnO3 (LSM) and yttria stabilized zirconia (YSZ) for use in solid oxide fuel cells (SOFCs) have been produced by air plasma spraying. Deposition was carried out using axial powder injection for increased deposition efficiency and composition control. A number of composite cathodes were produced using different combinations of parameter values within the identified range. Successful coatings were then characterized for composition and porosity using EDX and SEM. As a result of these tests, combinations of input parameter values were identified that are best suited to the production of coatings with microstructures appropriate for use in SOFC composite cathodes.