Martin, great explanation. I liked the part about being a robot! I have written lots of motion control code for painting robots to get uniform coating thickness. There is always some wierd dynamic in the corners and creases that the operator can tweak to make it right, but overall, it is smooth, consistant, speed and overlap that gets the job done best.
We are working on robot control fiberglass chop sprayers now . . . getting people out of the chemicals is a big push in composite tooling manufacture these days.