The economic efficiency of spraying a frequently changing spectrum of parts is strongly dependent on the costs of planning the spray process. In many cases, the robot program for coating a three-dimensional surface is generated directly on the control unit computer. Programming results in costly downtime. At IWS, a technology for off-line programming of robots and CNC systems for thermal spraying (TS) and laser cladding (LC) was developed. Coating programs are developed using CAD data from a workpiece and checked with simulation software. All steps are accomplished off-line without influencing ongoing production. Off-line programming of spray processes for three-dimensional surfaces enables substantial time savings to be realized, more so with increasing part complexity. These programs enable a constant spray distance and traverse speed as well as a permanent spray angle of 90° to the substrate to be achieved.