This paper presents the results of a process optimisation study applied to the synthesis of thin 8YSZ films by electrostatic spray deposition (ESD). The goal was to obtain thin, dense and continuous 8YSZ coatings. Starting from a zirconium acetylacetonate in ethanol - butyl carbitol solution as precursor, the influence of the main process parameters -substrate temperature, nozzle to substrate distance and solution flow rate has been studied. The microstructure has been characterised by SEM imagery. The study allowed us to define a three dimensional domain of optimal values of the process parameters where dense and thin doped zirconia coatings were obtained for the employed nozzle geometry and solution concentration. (c) 2006 Elsevier B.V All rights reserved.