Integration of digital paint technology for vehicle manufacturing

Axalta and Xaar are collaborating to deploy digital paint technologies for the automotive manufacturing sector. This technical integration focuses on implementing overspray-free application systems to optimize the production of two-tone vehicle finishes and detailed graphics.

Operational Challenges and Collaboration
Automotive manufacturers face structural challenges when producing two-tone vehicle finishes, as traditional methods require complex masking, multiple process steps, and additional labor, which constrain design flexibility and increase material waste. To address these industrial requirements, Axalta partnered with Xaar. This collaboration combines Axalta's proprietary jettable coating chemistry with Xaar's industrial inkjet expertise, establishing a single technology development to scale precise paint placement without conventional masking procedures.

Technical Solution and Responsibilities
The technical architecture is based on the Axalta NextJet system, which utilizes drop-on-demand inkjet technology to dispense coatings. Xaar is responsible for providing the printhead capability, engineered to handle high-viscosity fluids beyond traditional inkjet parameters to meet industrial performance requirements. Axalta supplies the proprietary paint formulation designed specifically for digital jetting. Together, these components create an overspray-free application platform capable of precise digital coating placement on vehicle surfaces.

Deployment and Implementation
The physical deployment of this digital paint process targets automotive manufacturing lines producing light and commercial vehicles. During the implementation phase, the technology is tested directly with customers to integrate the printheads and high-viscosity fluid handling systems into existing vehicle decoration workflows. The operational potential for full-scale production lines was identified for early 2024, focusing on seamless hardware compatibility with existing factory infrastructures.

Applications and Use Cases
This digital application technology is utilized directly in the automotive sector for complex surface decoration. Functional use cases involve the precise placement of coatings for two-tone designs, bespoke patterns, and detailed images. Applying this technology stabilizes process efficiency by removing the necessity for manual masking and reducing the energy consumption associated with multiple curing and painting steps.

Results and Expected Impact
The integration of the digital paint system eliminates masking requirements and reduces the material waste inherent in conventional paint application. This technical shift contributes to a 30 percent reduction in carbon dioxide emissions for two-tone vehicle manufacturers. Regarding the system's mechanical capability, Graham Tweedale, Chief Operating Officer at Xaar, details the technical baseline, noting the implementation involves "making use of our printhead’s ability to handle fluids with viscosities way beyond what has traditionally been possible with inkjet."

Edited by Maria Brueva, Induportals editor – adapted by AI.

www.xaar.com