<p>In this paper, the contour prediction and process parameter optimization of planar aluminum coating prepared on 316L stainless steel substrate by low-pressure cold spraying technology were studied. By combining the computational fluid dynamics method and the Gaussian model, a new coating profile prediction system is proposed, which can accurately predict the cross-sectional profiles of single-point, single-channel and single-layer coatings. High-purity aluminum powder and 316L stainless steel substrate were used in the experiment. The effects of gas temperature, pressure, powder feeding rate, spraying angle and spraying distance on the deposition efficiency of the coating were analyzed by numerical simulation and experimental verification. The results show that the spraying speed and scanning distance are the key factors to control the coating thickness and surface waviness. Based on this, a MATLAB reverse calculation program was developed, which can reversely derive the optimal spraying speed and scanning spacing according to the specified coating thickness and waviness, and achieve accurate control of coating thickness and surface quality. The experimental results show that the prediction model and the reverse calculation method have high accuracy and stability, which provides reliable theoretical support and technical tools for the industrial application of cold spraying technology.</p>