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La 0.6 Sr 0.4 Co 0.2 Fe 0.8 O 3-δ (LSCF) is a promising cathode material for solid oxide fuel cells (SOFCs). Hence, structured LSCF coatings were deposited in this study by atmospheric laminar plasma spraying (ALPS) at the spraying distances from 150 mm to 250 mm. Particles with high temperature were obtained at low plasma arc power of only 15 kW. The microstructural characterization of the coatings showed cluster-like morphologies on the top surfaces and columnar features with large-scale vertical cracks at the cross section. An evolution mechanism of the coatings was proposed based on particle size. The movement of particles during laminar plasma jet depended on particle size, which was studied experimentally and by simulation to explain the selective deposition. The coatings showed lower polarization resistance when compared to LSCF coatings deposited by atmospheric plasma spraying (APS) due to large vertical crack densities. The high output performance of the SOFCs with the LSCF cathode also proved this phenomenon. The results suggest that ALPS provides extensive options for SOFCs manufacturing. • LSCF coatings were deposited at the long spraying distances, although at low plasma arc power of only 15 kW. • The selective deposition depended on particle size was proposed to explain various structures of coatings. • Structured coatings with large-scale vertical cracks revealed lower polarization resistances compared to APS coatings. [ABSTRACT FROM AUTHOR]