Thermal Spray Toolkit (T.S.T.) is a developing toolkit based on ABB robot-studio software for thermal spray applications. It is composed of several function modules including trajectory generation, parameter decision, coating surface analysis, robot monitoring. The trajectory generation provides numerous methods to create trajectory on square surfaces, round surfaces, curved surfaces and rotating workpieces. The parameter decision permits users to select the right spray parameters according to a given material. The coating surface analysis determines the coating surface topography, coating thickness, etc. from the importing a given coating bead profile. The robot monitor can capture the real-time robot displacement during the spray process. T.S.T. is a toolkit developed to further develop robotics for thermal spray application. Experimentations and results show that this development is reliable and applicable.