This paper deals with the analysis of the evolution of the surface morphology of metal substrates coated with high-performance thermoplastic powders, namely PPA 571 H, by using electrostatic fluidized bed (EFB) process. Attention has been particularly focused on the relationship between baking time and temperature of EFB coated substrates and the morphological characteristics of the resulting polymeric films. First, thermal behaviour of PPA 571 H polymeric powders was characterized by using standard calorimetric techniques. Accordingly, PPA 571 H melting kinetic was experimentally deduced. Based upon experimental findings, predictive analytical model was also developed and employed to trace 'iso-conversion' curves out. Second, metal substra...