Every prototype trial that could have been avoided is a cost that compounds.
Book free consultationIntroducing PaintIQ
PaintIQ captures your actual spray pattern, characterises the atomizer, and hands your engineers everything they need to build an optimised robot program and predict film build on the real part geometry.
PaintIQ+ takes the measurement further: it reads your existing robot program, predicts film build across every layer in a digital twin, optimizes the path against minimum spec, and writes the approved program straight back to the controller.
Introducing PaintIQ
Engineers add 3 to 7 µm of safety margin per layer above the minimum spec because there's no reliable way to see the actual film build on a real 3D surface. At 300,000 bodies per year, that margin costs €825,000 annually.
Robot paths are optimized for flat plates, not real geometry. The result: up to 50% of sprayed paint becomes overspray on a BIW line — and on bumper lines, it can climb to 65%.
Three cells, 220 production days, one hour of plate measurement per cell per day. That is 660 operator hours per year spent on a method that gives you one number with no spatial information.
Programming a full car body robot path manually takes 120 to 200 hours. Each new colour, each new model, each facelift starts that clock again.
3 to 5 spray trials per model to validate film build. Each one requires physical measurements at up to 100 points on the part, and delays your SOP.
Your paint process runs on the experience of a few key people and because there's no automated daily QC record either, there's no baseline to compare against: deviations drift unnoticed until rework makes them visible.
PaintIQ delivers SB50 at 90 to 95% accuracy and predicts 3D film build at 90% accuracy across the full CAD geometry of your part. Not a flat plate, but the actual surface.
One sensor covers all three coating cells. Measurement takes 5 seconds per pass. The optimised robot program is generated automatically. Your engineers focus on decisions, not data collection.
Less overcoating means less paint consumed. Better transfer efficiency means less overspray. PaintIQ reduces material waste as a direct result of a more precise process, not as an afterthought.
BIW shop: €1.31M per year. Bumper shop: €1.1M per year. ROI of 7.0× for BIW and 14.1× for bumpers. Payback in under two months.
PaintIQ fits into your existing setup without friction. Fully standalone, ready within one day, and completely independent from your robot controller. Your production line keeps running while PaintIQ gets to work.
Unlike other systems that give you parameter suggestions and leave the changes to your engineers, PaintIQ reads and overwrites robot programs directly. The optimised path is ready to run.
The sensor is portable and moves freely between cells, meaning one investment covers everything. Maximum coverage, minimum overhead.
PaintIQ has been validated in collaboration with leading automotive manufacturers. SB50 accuracy of 90 to 95% and 3D film build prediction accuracy of 90% verified against physical measurement.
PaintIQ is the first spray measurement system that goes beyond analysis. It generates and writes the optimised robot program automatically, so your team can act on the data immediately.
The robot makes one spray pass through the laser sensor for 5 seconds. SB50 derived at 90 to 95% accuracy. Full thickness profile captured. Replaces the 60-minute plate, bake, and measure method.
The scanned SB50 enters the database. TCP and robot path are automatically derived from the CAD geometry of your part. Different overlap settings per surface zone are applied automatically.
Finds best brush settings virtually, no trial sprays. Tests brush sizes zone by zone for uneven film build. Validates new paints, colours, and applicators before production.
Generates full spray program from 3D CAD geometry only. Creates TCP trajectory and brushes for complex geometries. New model launch reduced from 12 weeks to 2 weeks. No manual path teaching required.
Optimizes path, returns updated program for manual apply. Minimises film build, reduces overcoating and overspray. Increases TE up to 20% by overspray reduction.
Optimized OLP program written back to robot controller. Engineer reviews and approves, or enables automatic write-back. Original program preserved, always reversible, no overwrite risk.
PaintIQ feedback
from the pilot customer
“The overall accuracy is approximately about 90%. The ESS software plays a very significant role in guiding the judgment of the trend and uniformity of the film thickness.”