To a great extent coatings for structural applications have been devel
oped by a combination of insight and empiricism. This approach has fai
led to provide a scientific and systematic base for future design and
development of new and/or improved coatings. The difficulty arises fro
m the innumerable process and structural parameters that need to be un
derstood and controlled accurately. Therefore, it is essential that fu
ture improvements or development of novel coatings take a multidiscipl
inary approach using fundamental principles related to equilibrium the
rmodynamics and process kinetics. Discussion is centered on the utiliz
ation of such an approach to formulate concepts that can aid in the de
sign and development of tailored coatings. Specific examples of severa
l coating systems currently under development are discussed. The inten
t is to show that the total solution to the systematic development of
customized coatings requires a combination of both fundamental analysi
s and a pragmatic process optimization approach.