German engineering MNC Dürr has introduced EcoNextJet, an advanced application system that prints complex graphics, patterns, and lettering directly onto vehicle surfaces in high resolution — horizontally, vertically, and even in two colors when required. 

 

By integrating custom designs directly into the painting process, the system replaces glued-on films and labor-intensive manual steps with a fully automated sequence that frees up production resources.

 

As demand for vehicle personalisation accelerates, traditional methods have struggled to keep pace. Until now, manufacturers relied on manually applying multi-layered films — often difficult to recycle, prone to visible edges, and limited in adhesion. EcoNextJet turns that painstaking process into a scalable, serial operation.

 

“The lines printed by EcoNextJet are as fine as a human hair. Regardless of the geometry or alignment of the body, detailed designs with high surface quality are possible in almost any location. Once the graphic has been clear coated, you can’t feel it anymore,” says Timo Beyl, Manager New Technologies at Dürr.

 

At the heart of EcoNextJet is drop-on-demand technology. A printhead equipped with 2,000 individually controllable nozzles is mounted to a painting robot. Each nozzle releases paint only when required, dispensing up to six drops per pixel. The droplets merge mid-air before reaching the vehicle body, enabling extraordinary control over size and speed.

 

The result: a paper-thin image with a paint film thickness of approximately five micrometers and resolution up to 720 dpi. A two-channel printhead allows two colors to be applied simultaneously. Specially developed software calculates the precise impact point of every drop — even on convex or vertical surfaces — while using the same paint across all surfaces to ensure a consistent finish.

 

EcoNextJet was developed through close collaboration. Dürr led process integration, robotics, and painting software. Axalta formulated the specialized paints. XAAR supplied the printhead technology.

 

“Our customers want their designers to have more freedom, especially when it comes to high-resolution graphics. The partnership with Axalta and XAAR significantly shortened the development time and made it possible to offer a complete system that meets the automotive industry’s requirements,” says Frank Herre, Director Automotive (Paint Shop) at Dürr.

 

EcoNextJet is now available for initial testing at Dürr test centers in Bietigheim, Germany, and Southfield, Michigan. Manufacturers can see firsthand how automated painting can produce high-resolution graphics without films, reduce waste, and cut labour time.