Thermosetting　powder　coatings　(TPCs)　undergo　several　processes　from　preparation　to　curing　on　the　substrate　surface.　Existing　research　works　and　reviews　have　mainly　focused　on　modifying　coatings　or　adjusting　their　formulations　to　improve　their　properties.　Material　properties　as　well　as　the　spraying　and　curing　processes　also　have　a　significant　effect　on　the　coating　quality.　Nevertheless,　a　comprehensive　discussion　regarding　the　effects　of　various　processes,　from　coating　preparation　to　the　curing　process,　on　the　coating　quality　is　still　lacking.　To　improve　the　coating　quality　of　TPCs,　this　review　discusses　the　effects　of　the　coating　properties,　substrate　properties,　spraying　methods,　curing　methods,　and　curing　parameters　on　coating　quality.　In　addition,　different　methods　for　evaluating　the　coating　quality　are　compared,　along　with　various　curing　kinetics　and　heat-transfer　models　used　to　describe　the　curing　process.　The　literature　shows　that　nano-modification　can　significantly　improve　the　coating　mechanical　properties　and　corrosion　resistance.　Furthermore,　the　hot　mixing　method　and　ultrasonic　pretreatment　efficiently　increase　the　loading　limit　of　nanoparticles.　In　the　subsequent　spraying　process,　the　electrostatic　spraying　method　enables　a　flexible　control　of　the　coating　thickness,　and　its　application　to　non-conductive　substrates　is　the　focus　of　future　research.　Regarding　the　curing　process,　infrared　curing　can　ensure　a　good　coating　quality　and　significantly　reduce　the　curing　time　(by　50　%-90　%　compared　with　traditional　hot-air　curing),　but　its　application　to　thermally　sensitive　substrates　remains　challenging.　Combined　curing　approaches,　which　integrate　the　advantages　of　different　curing　methods,　could　be　used　to　achieve　a　balance　between　efficiency　and　quality.　Furthermore,　coating　manufacturers　usually　only　provide　the　curing　parameters　for　hot-air　ovens.　Thus,　establishing　a　database　of　curing　parameters　for　other　curing　methods　is　urgently　required　to　guide　the　research　and　development　in　this　field.　After　the　curing　process,　a　wide　range　of　techniques　and　standards　are　used　to　assess　the　coating　quality,　which　is　among　the　fundamental　reasons　behind　the　discrepancies　and　non-comparability　of　the　literature　results.　Thus,　the　development　of　a　uniform　system　for　evaluating　the　coating　quality　is　also　required.　Finally,　the　current　description　of　the　heat-transfer　process　in　coatings　is　based　on　one-dimensional　models　and　ignores　the　mass-transfer　phenomenon　that　occurs　in　wood　substrates.　Therefore,　using　such　models　to　describe　the　complex　heat-transfer　process　of　coatings　may　lead　to　significant　errors.