With its combination of high resolution, automation and process integration, EcoNextJet aims to enhance both design flexibility and sustainability in vehicle production.
Dürr has unveiled EcoNextJet, a new automated application system that prints complex graphics, patterns and lettering directly onto vehicle bodies as part of the painting process. Designed to replace films and labour-intensive manual steps, EcoNextJet integrates custom designs into series production, offering manufacturers a faster and more resource-efficient approach to vehicle personalisation.
The trend towards customised vehicles continues to grow, yet until now elaborate designs have typically been applied using multi-layer films that are manually affixed to body surfaces. These films can be difficult to recycle, may leave visible edges and often provide limited adhesion. EcoNextJet automates this stage, transferring creative designs directly into the paint shop process.
“The lines printed by EcoNextJet are as fine as a human hair. Regardless of the body’s geometry or alignment, detailed designs with high surface quality can be applied in almost any position. Once clear coated, the graphic is no longer perceptible to the touch,” has stated Timo Beyl, Manager New Technologies at Dürr.
The system is based on drop-on-demand technology. A printhead equipped with 2,000 individually controllable nozzles is mounted on a painting robot. Each nozzle releases paint only when required, with up to six drops per pixel. During flight, the droplets merge into a single larger drop before reaching the vehicle surface.
This approach enables highly precise control of drop size and speed. The result is a paper-thin image with a paint film thickness of around five micrometres and a resolution of up to 720 dpi. A two-channel printhead allows two colours to be applied simultaneously.
Specially developed software from Dürr controls the robot’s path and calculates the exact point of impact for each drop, including on vertical or convex surfaces. The same paint is used across all surfaces, helping to simplify the process and ensure consistent finish quality.
EcoNextJet was created through a partnership between Dürr, Axalta and XAAR. Dürr was responsible for process integration, robotics and software; Axalta developed the suitable paint materials; and XAAR supplied the printhead technology.
“Our customers want to give their designers greater freedom, particularly for high-resolution graphics. Working closely with Axalta and XAAR significantly reduced development time and enabled us to deliver a complete system that meets the automotive industry’s standards,” has added Frank Herre, Director Automotive (Paint Shop) at Dürr.