Dürr Enables High-Resolution Direct Vehicle Printing

In automotive manufacturing and paint shop operations, integrating customized vehicle graphics directly into the production line is becoming increasingly relevant. With EcoNextJet, Dürr introduces a new application system that prints high-resolution designs directly onto vehicle bodies, eliminating films and manual application steps while maintaining industrial paint quality.

Direct integration into the painting process
Traditional vehicle personalization relies on adhesive films that are manually applied, often multi-layered and difficult to recycle. These films may create visible edges and require additional process steps. EcoNextJet replaces this approach with an automated sequence integrated into the painting process.

The system enables horizontal and vertical application of graphics, lettering, and patterns directly on the body shell. After clear coating, the printed design is fully integrated into the surface and no longer perceptible by touch. According to Dürr, line structures can reach fineness comparable to a human hair, allowing precise and detailed results even on complex geometries.




Drop-on-demand technology for micron-level precision
EcoNextJet is based on drop-on-demand technology. A printhead with approximately 2,000 individually controllable nozzles is mounted on a painting robot. Each nozzle dispenses paint only when required, with up to six droplets per pixel. During flight, droplets merge before reaching the surface, allowing highly controlled drop size and placement.

The resulting paint layer has a thickness of approximately 5 µm and supports resolutions up to 720 dpi. A dual-channel printhead allows simultaneous application of two colors. The same automotive paint used in the standard painting process is applied, ensuring consistent appearance and compatibility with existing coatings.

A dedicated software solution calculates the precise droplet impact point and robot trajectory, including compensation for curved or vertical surfaces. This ensures repeatable accuracy in serial production environments.




Partnership-driven system development
The EcoNextJet system was developed through collaboration between Dürr, Axalta and XAAR. Dürr contributed process integration, robotics and software expertise; Axalta developed suitable paint formulations; and XAAR supplied the industrial printhead technology.

This cooperation resulted in a fully integrated system designed to meet automotive production requirements in terms of quality, durability and process stability.




Resource efficiency and new design flexibility
By eliminating adhesive films, EcoNextJet reduces material waste and simplifies recycling. The automated process reduces manual labor and supports consistent quality in high-volume production.

For automotive OEMs, the system enables scalable customization strategies without disrupting existing paint shop workflows. It supports increasing demand for individualized vehicle designs while maintaining industrial efficiency.

EcoNextJet is currently available for evaluation in Dürr’s test centers in Bietigheim, Germany, and Southfield, Michigan, USA, where manufacturers can assess integration into existing automotive production lines.

www.durr.com