Plasma transferred arc (PTA) welded coatings are used to improve surface properties of mechanical parts. Advantages are the high reliability of the process and the low dilution of substrate and coating material. Processing of surfaces by PTA welding is restricted at the time to flat horizontal position. Furthermore, industry is interested in the development of strategies for coating with PTA in constraint position as complex three-dimensional (3D) parts could be then easily processed as well. Under commercial aspects, the process design can be optimized to increase process efficiency and to reduce heat input during the welding process. Process optimization involves the determination of guidelines for PTA welding in constraint positions as well. Modeling the process gives an alternative to reduce the experimental effort to optimize the welding process. Results of simulation studies of the PTA welding process are given in the present work. It will be shown that coating conditions can be optimized by varying plasma gas flow, heat input and heat flow, process speed, or powder injection with regard to welding in constraint positions. The defined controlling of the PTA welding allows modification of process management with less experimental effort and to develop coating strategies for processing in different positions. In experimental investigations, the developed coating strategies are confirmed by producing PTA coatings in constraint position as well as complex 3D parts.