Senior Design project at Texas State University. Challenged by Curtis Wright to find a reusable solution to polymer tape masking for HVOF (high velocity oxy fuel) and Plasma arc coating for aerospace components. My group leveraged advanced high temperature additive manufacturing in Ultem 1010 to replace polymer tape masking. HVOF and Plasma arc processes are extremely abrasive and high temperature, pushing the limits of whats possible with thermoplastic polymers. Our cost estimates show a saving of $150,000 per year for Curtis Wright Manufacturing and room to scale for even more savings. Because of the lack of fixed tooling the process is adaptable to any component. This is a novel solution to an extremely expensive and time consuming problem.