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Thermal barrier coatings were introduced to reduce operatingtemperatures and thermal stresses in structures and machine components across a widerange of industries and applications more than 40 years ago. Recently a new, relativelysimple and low cost manufacturing method of thermal barrier coatings based upon theslurry spray technique has been developed with a focus on aerospace applications. Thechallenge in the development of this technique was to achieve the coating qualitycomparable to the existing manufacturing methods, which are often expensive andinapplicable to coat large or curved surfaces. This paper describes the developedtechnique and presents selected results of thermo-mechanical and fracture testing of thethermal barrier coatings including graded coatings fabricated using this new method.