Dürr EcoNextJet prints individual designs on car bodies

The trend towards customizing vehicles continues unabated. Until now, elaborate patterns or lettering have been applied manually - often as multi-layer films that are difficult to recycle, whose edges are noticeable and whose durability is limited. EcoNextJet automates this labor-intensive step and transfers creative design to the series production process. "The lines that EcoNextJet prints are as fine as a human hair. Regardless of the geometry or alignment of the bodywork, detailed decors with high surface quality can be achieved at almost any point. After coating with clear lacquer, the graphics can no longer be felt," says Timo Beyl, Manager New Technologies at Dürr.

Drop-on-demand: painting in the finest resolution

EcoNextJet is based on drop-on-demand technology. A print head with 2,000 individually controllable nozzles is attached to a painting robot. Each nozzle only releases paint when it is needed. Up to six drops can be created per pixel. They combine during the flight to form a larger droplet before they reach the surface. Size and speed can therefore be controlled very precisely. Point by point, an image is created with a resolution of up to 720 dpi, which is wafer-thin with a paint layer thickness of around five micrometers. The dual-channel print head can process two colors simultaneously. Software specially developed by Dürr controls the robot path and calculates the impact point of each drop, even on curved or vertical surfaces. The paint is the same for all surfaces.

Cooperation between Dürr, Axalta and Xaar

EcoNextJet was developed in close cooperation: Dürr took on process integration, robotics and software for the painting process. Paint manufacturer Axalta developed the appropriate paints and printhead manufacturer Xaar contributed the printhead. "Our customers want their designers to have more freedom - especially when it comes to high-resolution graphics. The partnership with Axalta and Xaar has significantly shortened the development time and made it possible to offer a complete system that meets the requirements of the automotive industry," says Frank Herre, Director Automotive (Paint Shop) at Dürr. EcoNextJet is available for initial tests at Dürr's test center in Bietigheim. There, manufacturers can test how graphics and patterns are created in an automated painting process that eliminates the need for film, reduces waste and saves working time. At the same time, the high resolution opens up new scope for design. EcoNextJet is therefore not only a technological innovation, but also a path to more efficient and sustainable processes in vehicle production.