The BMW Group 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 available to 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.

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 approximately 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. BMW says 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 produced using manual masking. With the new technology, the material and personnel costs this previously entailed will be eliminated, making the process less expensive. This innovative process also prevents overspray and reduces energy consumption, reducing the carbon footprint by nearly 2,000 tonnes per year.