+++ BMW Group Plant Dingolfing pilots new paint
process +++ Overspray-free paint application opens up a wide range of
possibilities for customisation +++ Unique combination of customer
benefits and sustainability +++ Technology boosts both resource and
energy efficiency +++
Munich / Dingolfing. BMW Group Plant Dingolfing is
piloting a new overspray-free painting process that allows several
paint colours to be used and designs to be applied without stencils or
masking the vehicle. The highly innovative application method not only
increases the degree of individualisation for customers, but also
contributes to sustainability by reducing waste and energy
consumption. The technology is being used for the first time in 19 BMW
M4 Coupés, which will soon roll off the production line at Plant
Dingolfing with custom two-tone paintwork and M4 identification on the
bonnet and tailgate.
Milan Nedeljković, member of the Board of Management of BMW AG,
responsible for Production: “We expect the highest standards of
efficiency, sustainability and digitalisation from our production.
This smart painting technology meets all the requirements for an
innovative production process and also offers unique customer benefits.”
The BMW Group developed the new EcoPaintJet Pro application process
for waterborne base coats and 2K clear coat in collaboration with
mechanical and plant engineering firm Dürr. In the conventional
procedure, paint is atomised by a rotating bell with 35 to 55,000
revolutions per minute and adheres electrostatically to the body. The
new method works without electrostatics, relying instead on jet
application. The paint is applied using an orifice plate that enables
high edge definition with a variable paint thickness of between 1 and
appr. 50 millimetres. This requires maximum precision from both the
robot and application technology. It also means two different colours
of paint can be used, e.g. for a contrasting roof, and stripes and
other designs applied – for instance, on the bonnet. The focus of
technology and material development was on achieving the maximum range
of applications. It will now be possible to paint every exterior
component – offering customers virtually limitless options for individualisation.
Until now, custom designs like this can only be realised using manual
masking. With the new technology, the material and personnel costs
this previously entailed will be eliminated, making it possible to
realize these options at a lower cost. This innovative process also
prevents so-called overspray, i.e. excess paint particles, which
therefore no longer has to be disposed of. A further contribution to
sustainable production comes from lower energy consumption: Since
paint separation is no longer required, the amount of air needed is
also lower. At around 7,000 operating hours, this results in energy
savings of more than 6,000 megawatt hours and reduces the carbon
footprint by nearly 2,000 tonnes per year. Development of innovative
paint technology for further series applications will continue.
With the paintwork for the M4 small series, the BMW Group is testing
the possibilities of the new process. These unique vehicles will
initially be used in the company’s own fleet. Series introduction of
the piloted paint process is scheduled to begin in 2022 in the BMW
Group production network.