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A novel numerical methodology is proposed to simulate thermal spray coating process on 3D objects with a focus on the prediction of the footprint shape and thickness. The method is based on the level set approach to capture the evolution of the deposited layer interface during the coating process. The shadowing effects that strongly affect the final footprint on 3D objects are considered. The method allows for the imposition of complex source trajectory and orientation evolution which are requested to tailor the final footprint on complex 3D objects. The capabilities and limitations of the proposed numerical tools are assessed using an aeronautic test case: the thermal spray coating of a part of aircraft engine (seal teeth). [ABSTRACT FROM AUTHOR]