<p>Modern intelligent thermal spraying technologies offer substantial advantages over conventional methods, enabling higher efficiency, reduced material waste, and improved automation in the deposition of thermal barrier coatings for aeroengine blades. These advancements minimize manual intervention while enhancing system integration through advanced human–machine interfaces. This review systematically examines the core components of intelligent thermal spraying systems. It begins with modeling approaches for kinematic parameters and coating thickness prediction, followed by an in-depth discussion of in-process technologies such as blade data acquisition and analysis, trajectory planning and optimization, virtual simulation, and robotic calibration. The interdependencies among these modules are highlighted to reflect the integrated nature of modern spraying workflows. Post-spraying, the mechanisms of defect formation and relevant non-destructive testing methods are explored. The review concludes with a comparative assessment of intelligent and conventional spraying systems, outlining current challenges and proposing directions for future research.</p>