Application: Paint high-gloss surfaces on plastic and metal with minimal defects
What this application is about
In practice, solutions range from flexible manual workstations to indexed, robot-assisted series-production systems. The spray equipment, material supply and movement sequence must be suited to the coating material and the workpiece.
What defines a high-quality high-gloss surface
The application mainly concerns plastic, steel, aluminium, magnesium and pre-treated composite components. The required effect occurs only when coating material, substrate, layer thickness and subsequent drying or curing fit together. The spraying process must therefore be adapted to the concrete material system and the real production conditions.
Alongside surface quality, material consumption, cleaning effort, system availability and reliable repeatability also matter. A sound technical solution therefore combines controlled atomisation with a stable material supply that is easy to regulate.
Typical requirements for the spraying process
Even small fluctuations in material pressure, viscosity, distance or movement control can change the coating visibly or functionally. Typical requirements include:
- visible dust particles, clouds, orange peel and runs
- uniform wetting and levelling on large visible surfaces
- constant material pressure and reproducible spray pattern
- clean edge and geometry cover
- Matching of multilayer lacquer bodies
- high requirements for cabin air and component cleaning
Spray pattern, levelling and cleanliness
High gloss surfaces make orange peel, dust, clouds, runs and smallest layer variations visible. Fine atomisation alone is not enough: the quantity of material, spraying distance, overlap, ventilation and varnish viscosity must allow a uniform course.
In plastic parts, surface, pre-treatment and possible solvent reactions are added. In the case of metal, the complete coating structure determines the corrosion and adhesion properties.
- fine atomisation with sufficient wet application
- Uniform overlap
- controlled environment and component cleanliness
- Avoidance of runs at edges and radii
- matched ventilation and drying conditions
Krautzberger solutions for spray application and material supply
Krautzberger treats application and material supply as a connected system. Depending on the task, manual and automatic spray guns, suitable air and material nozzles, material pressure tanks, diaphragm pumps, pump and lifting stations, and material pressure regulators can be combined.
In automated processes, spray guns can be integrated into mounts, lifting devices, axes or robots. Material changeover valves and flushing equipment support applications with several colours or media. The specific selection depends on viscosity, solids content, application quantity, cycle time and component geometry.
For fine surface finishes, various XLINE nozzle combinations and spray patterns are available. With highly viscous, abrasive or sedimenting media, sufficiently large flow cross-sections, suitable material combinations, agitators and pressure-stable delivery become more important.
The focus is on finely atomizing hand paint guns and automatic spray guns, high-quality flat jet nozzles, precise material pressure regulators, clean pressure vessels or pumps, and in series robotics. The technically and economically suitable combination is selected for the specific medium, components and required production output.
Components, industries and fields of application
The application is used in different industries and component groups. Typical examples are:
- Piano Black Components
- Automotive interior and exterior
- Housing and design components
- Household and electrical appliances
- Furniture and fittings
- Watch, luxury and consumer goods components
Manual, partially automated or fully automatic
Constant spray conditions and overlapping webs are required for high visual quality. Speed, distance, alignment and switching points are reproducibly stored in automated systems.
In addition, component feed, extraction or ventilation, cleaning, media change and accessibility for maintenance work must be taken into account during the system integration. This keeps the process stable not only in the pattern run, but also in everyday production.
Result for quality and economy
- even shine and good finish
- less optical reject errors
- Reproducible visual quality
- reduced overspray due to suitable spray pattern
- flexible for manual and automatic processes
- coordinated supply for sensitive varnishes
Tests with original material and sample components
Liquid media and coating materials with similar names can differ considerably in viscosity, solids content, solvent base, wetting and drying. A reliable choice of spray gun, nozzle and material supply should therefore be made using the original material and a representative component.
Samples are evaluated under strip and control light. spray pattern, course, layer thickness and drying are optimized together.
On this basis, the spray pattern, material quantity, pressure, distance, movement and cleaning sequence can be defined. The result is an application solution suited to the medium, the geometry and the intended production process.
Trials at the Krautzberger technical centre
At the Krautzberger technical centre, the process can be tested with the original medium and representative sample components. Conveyability, spray pattern, application quantity, material pressure, distance, movement and cleaning are coordinated during these trials.
The trials provide a reliable basis for selecting the spray gun, nozzle, material supply and degree of automation. Final functional and process approval is issued by the operator together with the material manufacturer.
Related products
All products
Contact for your application
Looking for a spray gun, an automatic spray gun or a complete material supply for this process? Krautzberger helps you select and design suitable spray technology, nozzle configurations, delivery and regulation.
Contact Krautzberger to discuss your medium, component, production volume and desired result. Together, we assess how the process can be implemented safely and economically.
Industries for this application
A high gloss finish makes differences in surface, coating and drying quickly visible. In the case of vehicle parts, plastic components or components in furniture construction, material and shape vary, but the demand for a uniform look remains.
