Dürr Systems AG has developed EcoNextJet, a new application system that integrates individual designs directly into the automotive painting process. Graphics, patterns, or lettering are printed directly onto the vehicle surface without the need for foils or manual intermediate steps. Once the clear coat has been applied, the motifs are integrated into the paint layer.
The system is based on drop-on-demand technology. A print head mounted on the painting robot with more than 2,000 individually controllable nozzles dispenses paint with pinpoint accuracy. Each nozzle works as needed, so that several drops can be generated per pixel and brought together in a targeted manner during flight. This results in a high-resolution print image with up to 720 dpi and a paint layer thickness of around five micrometers.
Precision on complex geometries
EcoNextJet processes horizontal and vertical surfaces equally well. Software calculates the robot path and the exact point of impact of the drops, even on curved or vertical body areas. The two-channel print head allows two colors to be processed in the same process step.
Compared to conventional decorative films, there is no need for additional material layers and manual work steps. The aim is to achieve an automated process in the existing paint line.
Development partnership for series applications
Dürr was responsible for process integration, robotics, and software development. Paint manufacturer Axalta developed suitable paint systems for direct printing, while XAAR contributed the print head. The system is available for validation and application testing at the test center in Bietigheim-Bissingen.