This paper presents a novel path generation method designed to reduce conflicts between excessive gaps or overlaps and laying defects on complex surfaces. First, a defect model is established for complex surfaces. Then, a mathematical model is formulated to calculate laying gaps based on path laying angles. By integrating these two models and introducing gap and angle optimization variables, a path optimization method is developed, constrained by both laying gaps and defects. The accuracy of the mathematical model is validated across various types of surfaces. Results show that, with appropriate parameter selection, the model’s maximum prediction error is 0.04 mm. A comparative study is conducted with a conventional path generation method on a complex surface. The laying gap range is reduced from −4.9 mm to 12.3 mm to an engineering-acceptable range of 0 mm to 2.5 mm, with no observed laying defects, thereby demonstrating the effectiveness of the proposed method.
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