Spray coating is a versatile, simple, efficient, and most widely used technique for applying a thin layer of material to a surface. Spray coating has many advantages such as handle wide range of material and thickness, uniform coating on complex shape, scalability, cost efficient, waste reduction as compared to dipping & brushing, automated for high volume production, reducing labor cost and improving consistency. There are several distinct type of spray processes that can be used in aerospace application such as cold spray. But the selection of spray coating process for an aerospace application depends upon many factors such as target properties (corrosion resistance, wear resistance, etc.), desired coating materials, substrate limitations, and cost considerations. This chapter presents an overview of the various spray coating process, Types, preparation of MWCNT/epoxy nanocomposite films, spray coating process of MWCNT/epoxy nanocomposite films, MWCNT/epoxy nanocomposite films for aerospace applications, future trends and distinct challenges are discussed in detail.