Automotive Bumper Robotic Coating

Project Background

The client is a Tier-1 bumper supplier to a major OEM in Argentina, with annual supply volume of 800,000 pieces. New vehicle programs required A-class film quality (no flow, orange peel, or color variation permitted).

The Challenge

Bumpers are PP plastic parts, nearly 2 m long, with complex curves and recessed structures. Three coats (primer-color-clearcoat) all requiring excellent quality, with cycle time below 60 seconds.

MUSI's Solution

MUSI designed a 10-robot ABB flexible coating line: 1 loading robot + 6 spray robots (2 per coat working in pairs) + 1 inspection + 2 unload. Full MES integration provides full traceability for every bumper's spray parameters.

Equipment Configuration

Robots	10 ABB IRB52 (spray)
External axes	2-axis manipulator at each station
Coating system	Primer + base color + clearcoat
Film thickness	Primer 25±5 μm, color 20±3 μm, clear 35±5 μm
Cycle time	60 sec/piece
Daily capacity	1,200-1,400 pieces
Color portfolio	8 mainstream colors, 5-min change
MES	Quality traceability supported

Implementation

120-day delivery. Robot offline programming was the key — MUSI worked with ABB's regional team to optimize trajectories for each bumper SKU, ultimately confirming 28 standard programs.

Results

After commissioning, the line passed OEM coating certification. Visual pass rate 99.6% — industry-leading. The client won exclusive supply for new vehicle programs, growing annual revenue by $7 M USD.

Client Feedback

"Automotive industry quality demands can only be met reliably by robots. MUSI's process solution met our most demanding supplier standards."
— Project Manager, Client Side

Get a Similar Solution

If your industry and requirements match this case, contact MUSI to schedule a free consultation. We'll design an optimal solution based on your specific workpieces, capacity, and facility.