Fraunhofer IPA at the PaintExpo 2026: Research projects presented

At PaintExpo in mid-April, the Fraunhofer Institute for Manufacturing Engineering and Automation IPA will be providing insights into current research projects relating to efficiency, digitalization and sustainability in surface technology. Among other things, the focus will be on simulation-supported pre-treatment processes, AI-monitored painting processes and a water-based zinc primer. Under the motto "Finishing for Compliments", the researchers will be presenting approaches designed to help coating companies achieve more sustainable and smarter painting processes in Hall 1, Stand 1322 from April 14 to 17. These include the "DigiStrahl" project, in which a simulation-supported pre-treatment process for compressed air blasting is being developed. In this process, solid particles are shot onto metallic surfaces to create a uniform roughness for paint adhesion. Digital mapping and simulation make it possible to determine in advance which blasting agent and which parameters will deliver the best result. This reduces the use of blasting media and energy and reduces waste, especially in small and medium-sized companies.

Optimization of the painting process through artificial intelligence

Another focus is on optimizing the painting process using artificial intelligence. In the "pAInt-Behaviour" project, numerous tests with varying system parameters were carried out in the painting pilot plant and the process was monitored using around 30 sensors. The data obtained was evaluated using machine learning methods. This resulted in a behavioral model that detects impending quality deviations at an early stage and can identify causes in order to reduce rejects, rework and plant downtimes. Fraunhofer IPA is also presenting "EcoWaterZinc", a solvent-free, water-based zinc primer. Conventional zinc-containing coatings release volatile organic compounds during curing and can cause health problems. In addition, zinc reacts with water, which can impair the corrosion protection effect in the long term and cause environmental problems. The newly developed primer is based on modified zinc particles that do not react with water and thus enable a permanent anti-corrosive effect.