A new spray process allows for deposition below a critical velocity limit of cold spray, while providing adhesion. Post deposition heat treatment has shown excellent coating strength. A wide variety of materials can be deposited. The spray process is based on ShockWave Induced Spraying (SWIS) but with much slower spray jet projection velocities. High porosity, pore size control, and porosity control are demonstrated to be controllable. Preheating of feedstock and uniform temperature of the SWIS delivery allow for the deposition below critical velocity.