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High-velocity oxyfuel thermal spray processing was used to produce ceramic/polymer (silica/nylon) nanocomposite coatings. By optimizing spray parameters such as nozzle design, spray distance, oxygento-fuel ratio, powder feed position, and substrate cooling, dense coatings with relatively uniform particulate distribution could be achieved. Compared to pure nylon coatings, scratch resistance improved by 30 % and wear resistance by 50 %. The surface chemistry of the silica filler affected the final coating properties. Silica particles with a hydrophobic (methylated) surface resulted in better mechanical properties than those with a hydrophilic (hydroxylated) surface.