The paper presents a new method of path planning for an industrial robot manipulator performing thermal plasma spraying of coatings. Path planning and automatic generation of the manipulator motion program are performed using preliminary 3D surface scanning data from a laser trian-gulation distance sensor installed on the same robot arm. The new path planning algorithm is based on constructing a function of the geodesic distance from the starting curve. A new method for constructing a geodesic distance function on a surface is proposed based on the application of discrete exterior calculus methods characterized by high computational efficiency. The developed algorithms and their software implementation were experimentally tested through robotic mi-croplasma spraying of a protective coating on the surface of a jaw crusher plate, which was then successfully operated for crushing mineral raw materials.