Numerical simulations

By numerically simulating painting pre-treatment, painting application and paint drying processes, the following benefits can be achieved:

  • Minimization of complex and costly experimental tests
  • Rapid realization of parameter studies and optimizations
  • Planning support
  • Quick insight into the basic steps of the painting process and visualization of non-measurable parameters
  • Fast transfer from the model to the real situation

Through the extensive experience of Fraunhofer IPA, even small-sized companies can save time and money and improve their process reliability.

Fraunhofer IPA has adapted the method of simulating flow processes and electrical fields to painting technology requirements. The method is implemented as a tool for research, development and application purposes. We supplement commercial CFD tools with modules to calculate particle pathways, the distribution of layer thicknesses and application efficiency when coating any component geometry.

We have also developed a further computer program, which allows us to simulate dynamic coating processes on complex three-dimensional work pieces. To do this, we integrate the previously-calculated static spray image for a specified coating pathway.

All methods are validated in our technology centre and assessed for practical feasibility.


Examples of the successful implementation of numerical coating simulations conducted at Fraunhofer IPA:

  • Paint atomization patterns
  • Overspray and spread of solvents
  • Film formation and development of paint films
  • Powder coating with powder guns and fluidizing bed
  • Pneumatic feed of powder coatings
  • Drying process of paint films, temperature changes in paint layers
  • 2-component mixer
  • Sealing seams
  • Droplet separators
  • Thoracic particles