Automated robot tool trajectory planning for spray forming is highly desirable for today’s automotive manufacturing. Generating a robot tool trajectory to manufacture an automotive part to satisfy material distribution requirements is still very challenging due to the complexity of the problems. An industrial part may need to be partitioned into multiple patches because of its complexity. The trajectories of all patches must be connected to form a complete trajectory for the industrial part in order to minimize the material waste and process cycle time. In this paper, the methodology for automated robot tool trajectory connection is developed. Experimental tests were carried out to generate trajectories for automotive parts and the results validate the developed approach. A user-friendly software packages were developed and used at the Ford Motor Company to generate robot tool trajectories to manufacture automotive parts. The developed algorithm can also be extended to other applications in surface manufacturing such as spray painting.