A massage robot that helps to improve the quality of human life has attracted more interests of researchers and consumers. A portable back massage robot that is compact and space-saving was designed to be used on human back instead of a traditional large-scale structure robot. To design the massage robot, the models of electric circuit, magnetic circuit and mechanics were analyzed to achieve optimal massage force. Parameters of the massage actuator are determined based on the influence analysis of the coil current, the coil turns and the distance between the moving core and the yoke on the electromagnetic force. The massage coverage of human back, which is used to calculate the massage effect, could be improved by an excellent path planning algorithm. This article proposed an efficient full covered path planning algorithm for the designed massage robot, and the relevant algorithm models were established. Simulation results show that the coil current is much more sensitive to electromagnetic force of the moving core compared to the other two factors, and the presented path planning algorithm completes full coverage of the massage robot on the back area. The experimental platform of the massage robot was built, and the influence of the input signal duty cycle, the input signal voltage and the hardness of the massage object on the massage effect was discussed by testing the values of acceleration. The tested results show that the massage effect is best when the duty cycle is in the range of 1/8–1/2. Meanwhile, the hardness of massage parts affects the massage intensity. The consistency between the tested results of path planning and simulation verifies the feasibility of the simulation procedure and indicates that the massage robot can attain the desired massage performance and realize the planned paths.