BMW is testing a new spray-free paint process

The BMW Group plant in Dingolfing has a pilot program with a new spray-free painting process, which allows the use of more paint colors and the application of models without patterns or masking the car.

The highly innovative application method not only extends the degree of individualization to customers, but also contributes to sustainable development by reducing waste and energy consumption. The technology is being used for the first time on 19 BMW M4 Coupé cars, which will soon leave the Dingolfing plant’s production line, with custom two-tone paint and M4 identification on the hood and tailgate.

The BMW Group has developed the new EcoPaintJet Pro application process for water-based coatings and 2K clear coatings in collaboration with mechanical and plant engineering firm Dürr. In the conventional procedure, the paint is atomized by a rotating bell at 35 to 55,000 rpm and adheres electrostatically to the body.

The new method works without electrostatic application, relying instead on spray application

The paint is applied using a plate with a hole that allows a high precision adjustment of the layer with a variable thickness of paint between 1 and approx. 50 millimeters. This requires particularly precise control of both the robot and the application technology.

It also means that two different colors of paint can be used, for example for a contrasting roof or stripes. and other models applied, for example, to the hood. The development of technology and materials was achieved with a focus on obtaining a maximum range of applications. It will now be possible to paint each exterior component – giving customers virtually unlimited individualization options.

So far, such custom models can only be made using manual masking. With the new technology, material and personnel costs will be significantly reduced. This innovative process also prevents the so-called excess spray. An additional contribution to sustainable production comes from low energy consumption: at around 7,000 operating hours, this results in energy savings of over 6,000 MWh and reduces the carbon footprint by almost 2,000 tonnes per year. The development of innovative painting technology will continue for other series applications.

With the painting for the small M4 series, the BMW Group is testing the possibilities of the new process. The series introduction of the pilot painting process is scheduled to start in 2022.

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