This thesis work resulted in a template for how the thermal spray process can be controlled through robot programs. The robots today and their programs need to be replaced, therefore a new structure which can be matched with the new robot systems is needed. The work is limited to only concern structured programming on the new robots on Thermal Spray Centre (TC) with the programming language Rapid. The basic data for the program was retrieved from interviews with concerned personnel at TC, from studies on process parameters for thermal spray and from existing specifications at Volvo Aero Corporation (VAC). The thesis work briefly describes the process thermal spray and the four methods used at VAC. A literature survey on Jackson Structured Programming, Human Machine Interface and structured programming was made and used to compare, evaluate and suggest improvements for the thermal spray work cell. A functional suggestion for a menu system in a robot program for the thermal spray robot was presented. This will be in the robot permanently for uploading of detail programs from a network connected computer. An example of such a detail program was made but without robot movement and communication with the process computer. Testing of the programs has therefore only been made on a robot not suited for thermal spraying. The new detail program shows its parameters directly on the screen so they can be controlled against the operation papers. A programmer\2019s guide to the detail program has been made which is presented in the report.