AI-Driven Polymeric Coatings: Strategies for Material Selection and Performance Evaluation in Structural Applications

Polymeric coatings play a pivotal role in enhancing the durability, functionality, and sustainability of structural materials exposed to harsh environmental conditions. Recent advances in artificial intelligence (AI) have transformed the development, optimization, and evaluation of these coatings by enabling data-driven material discovery, predictive performance modeling, and autonomous inspection. This review aims to provide a comprehensive overview on AI-driven polymeric coating strategies for structural applications, emphasizing the integration of machine learning, computer vision, and multi-physics simulations into traditional materials engineering frameworks. The discussion encompasses AI-assisted material selection methods for polymers, fillers, and surface modifiers; predictive models for corrosion, fatigue, and degradation; and intelligent evaluation systems using digital imaging, sensor fusion, and data analytics. Case studies highlight emerging trends such as self-healing, smart, and sustainable coatings that leverage AI to balance mechanical performance, environmental resistance, and carbon footprint. The review concludes with identifying current challenges—including data scarcity, model interpretability, and cross-domain integration—and proposes future research directions toward explainable, autonomous, and circular coating design pipelines.