MD* is a thermal spray manufacturing process to rapidly form near net-shape objects. Optimizing the properties of objects manufactured by this process requires the understanding of the thermal history of the deposited material, particularly the occurrence of substrate remelting and substrate cooling rates. A mixed Lagrangian-Eulerian model accounting for remelting has been developed to investigate the effect of operating conditions such as droplet or substrate temperatures and droplet size on the remelting phenomenon and cooling rates experienced. Experiments are performed for molten carbon steel droplets impinging on a similar substrate to acquire input data for the model and results for comparison with numerical simulations.