Audi Develops New Process of Overspray Free Painting

Audi has developed a new painting technique that makes it possible to use two colors during one process. The new technology makes overspray‑free painting a reality. With the use of this technique, it is now possible for specific surfaces of a car body to be painted in different colors – all as part of one spraying process. Use of this new technique can help cut costs and is highly resource friendly. Audi has already tested this technology in a pilot paint shop at the company’s plant in Ingolstadt, with car bodies being painted in their designated colors while the roofs of the cars are painted in contrasting black.

It is no longer necessary to waste time and use up masking materials as it is now possible to paint without overspray. Earlier, for spraying a contrasting color, plant employees had to mask off the part of the car body which needed to be painted in a different color. This part then had to be painted separately with a second spray process.

In sharp contrast, a robot‑controlled high‑precision instrument now measures the laser‑brazed seam between the roof and the side‑panel frame before the painting process for each car begins. For overspray‑free painting, a special applicator then applies the black paint directly to the car body in individual strips with millimetre accuracy. The applicator places the strips of paint with sharp borders and without any spray mist – that is, without any overspray.

This innovative technique is not only environmentally friendly but also helps save money and time. From the environmental perspective, there is no more need for any masking material and it minimizes the amount of paint that is needed. Audi already has plans to use this innovative painting process in series production by next year. With the help of this process, Audi will be able to offer customers even more scope for individualization.