Artificial intelligence and automation have long been an integral part of industrial surface technology. Whether process monitoring, quality assurance, material efficiency or system control - digital technologies are fundamentally changing painting processes and raising them to a new level of performance. PaintExpo will pick up on this development and focus on intelligent, automated solutions from April 14 to 17, 2026, which are already being used in practice today and will become even more important in the future. The close exchange with manufacturers, system providers, research institutions and users shows that AI is no longer a promise for the future, but a decisive lever for more efficient, more sustainable and more stable coating processes.
Control layer thickness with AI in real time
AOM-Systems is a constant when it comes to sustainable processes and error minimization in the wet coating process. Data generated by AOM is the basis for AI, which automates and optimizes customers' processes. This enables users to use AI to rectify errors in the spraying process in a targeted and immediate manner. To do this, the operator receives a message from the AI about the exact cause of the error in the process. This reduces production errors and minimizes paint, energy and power consumption. As a result, AI now contributes directly to the conservation of resources and better use of production equipment. "A large OEM had to achieve a minimum coating thickness and set a high safety factor to achieve the minimum coating thickness even with small process fluctuations. With Spray from AOM, he can now control 100% of the coating application in real time. This saves a massive amount of coating thickness, material and alternative downstream controls and therefore money," says Managing Director Dr. Meiko Hecker, using a practical example to explain the benefits for users. During PaintExpo, AOM-Systems will be focusing on the integration of spray monitoring directly into the atomizer:
Convergent Information Technologies GmbH, the world's leading software supplier for paint repair with robots, is also using various manifestations of AI and machine learning. "This enables the automation of complex applications that seemed unthinkable just a few years ago. They allow a shorter start-up time, greater flexibility in production and faster integration of new products," explains Managing Director Dr.-Ing Christof Eberst. At PaintExpo, Convergent IT will be presenting the next generation of automatic planning for paint repair with robots and other surface processes. New input options for easier robot programming will also be presented, especially for low-cost systems.
Reduce energy consumption and overspray through automation
At Dürr Systems AG, the focus is on automation for wet paint systems. At PaintExpo, Dürr will be demonstrating live overspray-free painting with the EcoPaintJet and presenting the further development of the EcoSupplyP Core material supply system. This is a modular paint supply system with pigging technology and can be used wherever different paint colors are applied in smaller quantities, such as in the construction and wood industry or at automotive suppliers. Unused paint can thus be almost completely recovered, the consumption of rinsing agent minimized and the colour change accelerated. With the EcoPaintJet, overspray-free paint application has found its way into industrial vehicle painting, which paints with sharp edges and without any overspray. Now other branches of industry are also benefiting from this solution.
ESS Engineering Software Steyr GmbH specializes in the automation of the pre-processing step in meshing. This commitment to process automation extends across the entire simulation workflow. The solutions achieve considerable time and efficiency gains thanks to automation. For example, a vehicle development time can be reduced by up to one month and operating costs can be cut by around 30 percent. Reduced prototype costs, faster optimization and less dependence on experts can also be achieved with ESS solutions. Instead of around 600 kWh for painting a vehicle, the new patented painting technology from ESS reduces the energy requirement per car body to 200 kWh. In combination with CO2 reduction, increased material efficiency and waste avoidance thanks to digital prototypes, ESS customers save significant resources. At PaintExpo, ESS will be showcasing a range of automated processes and workflows across the entire simulation process.
Automation and AI in painting technology
As a leading developer of end-of-arm tools for sensitive surface processing - such as grinding, polishing or deburring - FerRobotics Compliant Robot Technology GmbH occupies a key position at the interface between high-precision mechatronics and advanced automation. With the help of its patented Active Compliant Technology (ACT), the company transfers sensitive manual processes to robot-supported series production. Thanks to active force control, automatic tolerance compensation and AI-optimized calibration, the ACT-based tools guarantee precision that leads to 100% reproducible results and enables perfect finishes even on sensitive surfaces. At the same time, efficiency is increased while process reliability is enhanced and the reject rate is minimized. At PaintExpo 2026, FerRobotics will be presenting the Active Taping Kit (ATK), a solution for automated masking, as well as a unique method for repairing paint defects on plastic (AOK 403) and new processing strategies for fast and intuitive programming.
Automation and AI are also an issue in powder coating. As an application manufacturer, Gema Switzerland GmbH has been relying on intelligent, networked control systems and control software for some time, such as the "MagicControl 4.0" system, which offers a powerful automation interface. In addition, selected concepts from Industry 4.0 can be used profitably in the powder coating process. Production data is continuously recorded, processed and visualized in a clear and informative way using tools such as the "GemaConnect Dashboard". The resulting added value for powder coating customers are material savings and increased efficiency. Precise control optimizes the powder quantity, which means less overspray and therefore less material consumption. However, AI and automation can also be used to achieve higher quality and consistency, reduce labor, improve process control and traceability with networked systems and real-time data, and increase safety for operators. At PaintExpo, Gema will be presenting a wide range of integrated functions that continuously improve industrial powder coating and support the sustainable use of resources.
Automation in conveyor technology and paint and varnish development
Automation also plays a central role at M&N Fördersysteme GmbH. The conveyor technology guarantees a continuous, stable material flow and ensures that all process steps in surface technology are precisely coordinated. As a result, M&N customers achieve high process reliability, efficiency and reproducible quality. Automated conveyor technology also makes an important contribution to conserving resources, as continuous and precisely controlled transport of the workpieces reduces downtimes and idle times, minimizes rework and ensures optimum utilisation of the coating systems. This leads to lower energy consumption, fewer rejects and more efficient processes overall. In Karlsruhe, M&N is focusing on new, enhanced rotary indexing conveyor systems and optimized control and guidance systems that offer greater flexibility in terms of cycle times and workpiece variants, improve the energy efficiency of the drives and enable an even more continuous, automated material flow.
In paint and coating development, ML-supported analysis methods enable formulations, recipes and application processes to be understood much more quickly and in greater depth. Pi Probaligence develops ML algorithms that are used across all industries in product development, process control and simulation. These models are increasingly being incorporated into control software, where they enable intelligent predictions and assistance functions. The more data-rich and automated a process is, the more effectively Pi Probaligence's solutions can be used. In product development, ML enables data-efficient, explorative test planning that specifically searches parameter spaces. This either finds an optimum or creates a digital twin that virtually maps complex real chemical and physical systems. At PaintExpo 2026, Pi Probaligence will be presenting concrete applications from industry and research and introducing a new interface with natural language control and automated connection to existing tools.
AI and automation as integral components of networked coating processes
The applications presented illustrate that AI and automation in surface technology are no longer viewed in isolation, but increasingly as integral components of end-to-end process chains. The focus is shifting from individual optimizations to networked systems in which process data, quality information and system parameters are combined and evaluated in real time. This development opens up new potential for reproducible quality, resource efficiency and process stability - but also requires a high level of system integration and reliable data models. PaintExpo 2026 reflects this level of technological maturity in the industry and offers a platform for professional exchange on the practical use, limits and further development of AI-supported solutions in industrial surface technology. (OM-2/26)
► Find out more about PaintExpo in our PaintExpo 2026 trade fair special (topics, exhibitor news and further information)