This review is based essentially on the results in the field of synthesis and characterization of plasma sprayed nanostructured coatings. Nanostructured ceramic coatings produced by plasma spray process are being developed for a wide variety of applications that require resistance to wear, erosion, cracking & spallation. It is anticipated that if properly deposited, nano structured ceramic coatings could also provide improved properties for a variety of applications, including wear resistance & thermal barrier coatings. This paper reviews: (a) the synthesis & characterisation of nanostructured feedstock powders; (b) the agglomeration of these powders for use in coatings; and (c) the processing of nanostructured plasma spray conditions.