Your study on experiential method is quite interesting. I had one research before comparing constructivism theory to experiential learning; Perhaps, it is good to start with that research and if you can possibly compare the results of your study with experiential studies done by David Kolb (1984). I also agreed and advocated this experiential method in his texts and publication
It may happen if substrate temperature is too high. At high temperature air currents are near the surface of the hot plate that pushes the mist away from the substrate.
You may push the mist with some more pressure towards the substrate or check the substrate temperature. If possible reduce it to some extent.
In spray pyrolysis technique, the most important parameters for film formation are; substrate temperature, the boiling point of your solvent, infuse rate of the solution and the carrier gas pressure. You should find a correlation between these parameters. These parameters determine if you will obtain a thin film or powder. I think your problem is directly related to these frameworks. The following book chapter explains the conditions for the film formation by spray pyrolysis. I strongly suggest you to investigate this book chapter.
If we don't know anything about the configuration of your deposition system, we can suggest a lot of "responses". Please, when looking for answers put your question as clear as possible.