ABB PixelPaint technology for electric vehicle paint shop

ABB's PixelPaint technology with the award-winning paint applicator, which works in a similar way to an inkjet printer, is set to go into series production at Mahindra & Mahindra Ltd in 2025. "Our revolutionary PixelPaint technology can paint large areas with uniform color as well as the smallest details with the highest precision, without delaying production and without manual intervention," emphasizes Jörg Reger, Head of the Automotive Business Line at ABB Robotics. "By using robots with PixelPaint in dedicated cells, Mahindra will be able to create finishes such as color-contrasting roofs and pillars for its new EV range in a fully automated process." PixelPaint consists of a paint applicator with over 1,000 tiny, individually controlled nozzles. It can be attached to an ABB robot such as the IRB 5500 painting robot. Combined with ABB's 3D vision system and coordinated by ABB RobotStudio planning and programming software, the applicator moves closely along the vehicle body to ensure that 100 percent of the paint is applied without overspray or excess paint mist. This eliminates the need for time-consuming masking and repeated passes through the paint line. There is no waste, yet the smallest details are faithfully reproduced.

The demand for personalization options has increased in recent years, and PixelPaint is just one example of how ABB's transformative technologies are helping to establish Mahindra's products in the luxury segment. The order, which builds on the existing relationship between ABB and Mahindra, also includes 42 robots from the IRB 5500 family. This makes M&M the first OEM in India to use PixelPaint technology for painting color-contrasting vehicle roofs and pillars. Complex and time-consuming operations such as interior painting and sealing are carried out completely autonomously, with the accuracy of ABB's systems ensuring that paint is applied precisely and only where it is needed. This eliminates the need for manual masking, saving time and materials. Similarly, ABB's RB1000i digital atomizers increase application efficiency by ten percent and reduce waste by over 30 percent by ensuring less paint is lost in the air.