This paper proposes a new methodology for robotic offline programming (OLP) addressing the issue of automatic program generation directly from 3D CAD models and verification through online 3D reconstruction. Limitations of current OLP include manufacturing tolerances between CAD and workpieces and inaccuracies in workpiece placement and modelled work cell. These issues are addressed and demonstrated through surface scanning, registration, and global and local error estimation. The method allows the robot to adjust the welding path designed from the CAD model to the actual workpiece. Alternatively, for non-repetitive tasks and where a CAD model is not available, it is possible to interactively define the path online over the scanned surface
