Innovative Coatings for a Greener Sky: The 2026 Strategic Roadmap for Thermal Spray and PVD Coatings

Abstract Decarbonizing aviation aims to reduce greenhouse gas emissions from aircraft operations, paving the way for sustainable air travel. This endeavor requires adopting advanced technologies, alternative fuels, high-performance coatings and efficient engineering solutions that minimize environmental impact while maintaining performance and safety standards. Two of the most prevalent and cost-effective methods for applying protective and functional coatings to aerospace components are thermal spray and physical vapor deposition. These techniques enhance the durability and efficiency of several components, resulting in fuel savings and an extended service life across the aviation industry. This supports the broader aim of transitioning the aviation industry to net-zero emissions and sustainable growth. This roadmap explores how these two coating techniques can promote sustainable aviation and identifies the challenges and opportunities in the aerospace sector for researchers and manufacturers of thermal spray and physical vapor deposition (PVD) coatings. It also proposes research directions to address these challenges and discusses the role of AI, which is crucial for breakthrough technologies in process optimization and integration, new coating development and coating design optimization. The roadmap is organized into 20 concise subsections, each focusing on a specific topic. Renowned specialists in each area were invited to summarize the current status of their field, discuss the challenges it faces, and offer recommendations for necessary research and development to overcome these issues. Together, these contributions vividly highlight the essential elements of the field and the challenges that lie ahead. The innovative ideas and concepts outlined in the roadmap reveal that the future path is both expansive and far-reaching.