The aim of this study is to improve suspension plasma spraying of zirconia doped with yttria in order to offer an alternative technology to the very costly electronbeam physical vapour deposition technique used for thermal barrier coatings in aeronautical industries. Diverse yttria stabilized zirconia coating architectures were obtained by slightly varying plasma jet thermophysical properties. Coatings were then submitted to isothermal cyclic fatigue tests. All of them displayed a lifetime corresponding to yttria stablized zirconia coatings produced by electron-beam physical vapour deposition.