Personalized, robot-controlled and overspray-free vehicle painting

With the paint applicator mounted on a painting robot, a car manufacturer coats vehicles and parts individually according to customer requirements. This is done precisely, without overspray and sustainably thanks to lower material consumption.

Mercedes-Benz has implemented ABB's innovative PixelPaint technology at its Sindelfingen plant, where it enables the precise and efficient painting of intricate designs in addition to conventional painting processes. The sustainable and resource-saving technology has been in use since 2025 and enables the manufacturer to develop new personalized options for its most exclusive models.

"PixelPaint uses an award-winning paint applicator that works similar to an inkjet printer and can paint both large colored areas and the smallest details with the highest precision," says Jörg Reger, Head of Business Line Automotive at ABB Robotics. "In a fully automated process that requires no manual intervention, the technology opens up new possibilities for vehicle manufacturers who want to meet customers' increasing desire for more personalization while reducing their emissions. We are delighted to have been able to help Mercedes-Benz realize these extraordinary design visions."

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. In combination with ABB's 3D vision system and coordinated by ABB RobotStudio simulation 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. No waste is produced, environmental pollution is reduced and overall emissions are lowered.

The technology is able to implement even highly complex designs with unsurpassed precision. At the same time, ABB's 3D vision system ensures high repeatability. This ensures that every painted body part is identical to the next.

"With PixelPaint, we are setting new standards in painting technology," says Arno van der Merwe, Head of Production Planning at Mercedes-Benz AG. "Combining the highest design quality and precision with innovative technical solutions is a milestone for the painting of our top models at the Sindelfingen plant. This pioneering technology takes us to a new level in individual paintwork, as it enables exclusive product results for our discerning customers."

Mercedes-Benz will first use PixelPaint technology for the Mercedes-Maybach SL 680 Monogram Series. To give the model even more exclusivity, the obsidian black hood is available on request with a filigree Maybach pattern in contrasting graphite grey. This extraordinary design could not be realized with a conventional process.

"We owe the success of this project to the close cooperation between ABB, the quality paint supplier PPG and the Mercedes-Benz project team," emphasizes Dr. Julia Schuchardt, Head of Process Development, Coating Technology and Corrosion Protection at Mercedes-Benz AG. "Looking to the future, we are already working on further developing the application so that we can offer our customers more color combinations and motifs."

PixelPaint is just one example of how ABB's intelligent technologies are transforming the painting process and completing the final piece of the puzzle in the digitalization of automotive manufacturing. With solutions such as the RB1000i-S digital-enabled paint atomizer - which achieves an application efficiency of up to 99 percent, reducing paint and material consumption - ABB is helping manufacturers become more sustainable, efficient and competitive. (OM-5/25)