Challenge
Just a few years after our founding, KSK developed a process that set new standards in high-gloss coating at the time: a patented curtain coating process for high-gloss B- and C-pillar trims with a piano-lacquer appearance. These components were among the most visible elements of a vehicle’s exterior. Accordingly, the requirements for surface smoothness, uniformity and reproducibility were extremely high. Originally, KSK coated them manually using a one- to three-coat build-up – with all the drawbacks of a process heavily dependent on the individual painter.
- Variable surface quality due to manual application
- Regular occurrence of orange peel and micro-inhomogeneities
- Extensive sanding and polishing work required during post-processing
- Limited process reliability and reproducibility in series production
- Rising manufacturing costs as OEM requirements increase
Solution
In the 1990s, KSK developed a patented curtain coating process in which components were robotically guided through a precisely defined curtain of coating. Unlike conventional spray coating, the coating was not atomised but poured evenly. The key was the combination of the curtain coating process, a specially developed and patented coating system, and precisely coordinated plant and process parameters. This completely eliminated any manual influence on surface quality.
- Robot-guided coating curtain instead of spray application
- Patented, specially developed coating system
- Precisely coordinated plant and process parameters
- Complete independence from the individual coater
Results
- Exceptionally smooth high-gloss appearance – comparable to lacquered glass
- Significant reduction in personnel required for post-processing
- Significantly improved cost-effectiveness compared with manual coating
- Stable series process with high pass rates
- Robust and reliable in day-to-day production
