Leaf-spray in vitro bioassays appraise new aphicidal formulations for managing deleterious plant-feeding aphids. The formulation may utilize alternative and integrated strategies. However, leaf spraying even under controlled conditions may affect aphid reproduction and mortality. This study examines leaf spray applications for optimum and reproducible aphicidal results using tobacco leaves overlaid on cotton fabric or water agar surfaces. Infestation of the undersides of tobacco leaves with nymphs of green peach aphids was used in the assays. Spray distance and volume were optimized using water-sensitive paper to ascertain the best surface coverage. Overlays of the leaves on water agar caused less mortality and greater reproduction than the use of cotton fabric. The relative humidity of the insect-rearing chambers changed with the watering regime for the insect - rearing chambers with cotton fabric; 60% relative humidity was optimal. Relative humidity was not affected by the concentration of agar in the water agar chambers. Applications of the chemical aphicidal standard, Sulfoxaflor, under the optimized conditions exhibited similar times for lethality although the rate was faster with leaves on the cotton fabric than on water agar. These studies establish reproducible and sensitive techniques for assessing the lethality and effects on reproduction of potential aphicidal products.