Self-Healing Polymer-Based Coatings: Mechanisms and Applications Across Protective and Biofunctional Interfaces

Abstract

Self-healing polymer-based coatings have emerged as a new generation of adaptive protective materials capable of restoring their structure and function after damage. This review provides a comprehensive analysis of current strategies enabling autonomous or externally triggered repair in polymeric films, including encapsulation, reversible chemistry, and microvascular network formation. Emphasis is placed on polymer–inorganic hybrid composites and vitrimeric systems, which integrate barrier protection with stimuli-responsive healing and recyclability. Comparative performance across different matrices—epoxy, polyurethane, silicone, and polyimine—is discussed in relation to corrosion protection and biomedical interfaces. The review also highlights how dynamic covalent and supramolecular interactions in hydrogels enable self-repair under physiological conditions. Recent advances demonstrate that tailoring interfacial compatibility, healing kinetics, and trigger specificity can achieve repeatable, multi-cycle recovery of both mechanical integrity and functional performance. A representative selection of published patents is also shown to illustrate recent technological advancements in the field. Finally, key challenges are identified in standardizing evaluation protocols, ensuring long-term stability, and scaling sustainable manufacturing. Collectively, these developments illustrate the growing maturity of self-healing polymer coatings as multifunctional materials bridging engineering, environmental, and biomedical applications.