Audi shows how to etch symbols into car paint

Audi has developed a process for the partial matting of painted surfaces.

A special powder roughens the clear lacquer on the surface to a depth of a few thousandths of a millimetre so that individual markings become visible. This process enables Audi to offer personalised design of the side blades for all R8 customers.

The process developed by the German carmaker’s experts makes each Audi unique. As the desired symbols are applied to components after being painted, the process can easily be integrated into normal series production. “The method of partial matting is an excellent example of the flexibility of our production. Being able to implement individualisation in normal series production is one of the aims of our smart factory,” said Prof. Dr. Hubert Waltl, Member of the Board of Management for Production at Audi AG.

Painting an automobile consists of – in addition to the cathodic dip coating to protect against corrosion – at least three further coats: filler, base coat and the transparent lacquer as the top protective coat.

How it is done

With the newly developed process, a template of the desired pattern is first placed on the component. A blasting system then sprays a special powder onto the surface, which roughens the clear lacquer to a depth of just a few thousandths of a millimetre – less than a tenth of the thickness of a human hair. This creates the effect of a matt and homogeneous pattern.

“With this process, we modify the brilliance of the paintwork and the intensity of its sheen. Light hitting the surface is then reflected diffusely by the individualised surface areas. This makes it appear matt,” said project manager Dr Erhard Brandl. Production section head Mirko Endres added, “This form of individualization is weather resistant, unlike conventional lettering and stickers, and it has a much more high-quality appearance.”

The Audi paint shop can apply almost any pattern that a customer might desire and which does not affect any third-party rights. At present, components with a size up to a metre by a metre can be processed in this way. The super sports R8 is the first model for which this technology is offered through the Audi exclusive individualisation program. If desired, R8 customers can have their individual lettering and graphics applied to the side blades of the Coupe and the open Spyder version. Audi plans to extend the offer to other models in the future.