Recent Advances in Spray Coating Technology for Carbon Fiber-Reinforced Polymer Composites: From Material Selection to Performance Optimization

As a highly promising surface modification technique, spray coating technology has opened pathways for fabricating high-performance carbon fiber-reinforced polymer (CFRP) composites. This review systematically illustrates recent progress in spray-based fabrication of CFRPs, with a core focus on elucidating the intrinsic relationships among "process-structure-performance". First, the basic design principles of spray coating technology are elaborated in detail, encompassing fiber pretreatment, spray material selection, fundamental parameter control, and typical spray techniques. These factors collectively highlight the significant potential of spray technology for high-end applications in aerospace, marine engineering, and electronic devices. Furthermore, advanced characterizations of the microstructures formed via spraying are introduced, revealing that precisely constructed interface engineering and multidimensional networks can actively optimize the distribution and transport of stress, heat, and charge within the composite. In addition, the intrinsic mechanisms of performance enhancement are deeply discussed, establishing a complete framework for mechanical reinforcement, thermal management, and electromagnetic integration. Finally, the review systematically summarizes the current research landscape and future challenges, emphasizing the need for breakthroughs in process standardization, characterization techniques, and performance design. This review provides valuable theoretical guidance and technical support for the rational design, process optimization, and industrial popularization of spray coating technology on CFRP composites.