Robotic Ultrasonic Spray Coating System
Kavin Inc designed, integrated and commissioned a turnkey robotic ultrasonic spray cell that applies uniform thin-film coatings with high repeatability and minimal material waste. The project covered complete cell design, robot programming, spray system integration and on-site handover.
The Challenge
The customer needed a precise, consistent coating on their components. Manual or conventional spraying led to uneven film thickness, overspray waste of costly coating material, and results that varied from operator to operator. They needed a repeatable, automated process with tight control over coating quality.
Our Solution
We built a complete robotic spray cell that combines industrial robot motion with ultrasonic atomisation. The ultrasonic nozzle produces a fine, soft, low-velocity spray, so more material lands on the part and less is lost as overspray. The robot follows programmed paths at constant speed and stand-off distance to support repeatable coating.
Scope Delivered by Kavin Inc
Cell Concept & Layout
Complete cell concept and layout design.
Robot Integration
Robot selection, programming and spray path optimisation.
Ultrasonic Spray System
Ultrasonic spray nozzle and generator integration.
Fluid Delivery
Precision fluid delivery and control integration.
Fixturing & Guarding
Part fixturing and safety guarding.
Commissioning & Handover
Commissioning, trials and operator training.
Key Features
- Uniform thin-film coating with repeatable thickness
- High material transfer efficiency, with less overspray and waste
- Programmable spray paths for different part geometries
- Consistent quality with reduced dependence on operator variation
- A cleaner, safer work environment for operators
Applications
Robotic ultrasonic spray coating suits industries that need thin, precise and uniform coatings, including:
- Defence components and equipment
- Aerospace parts and thermal or protective coatings
- Medical devices and stents
- Fuel cells, electrodes and battery components
- Glass, solar and optical coatings
- Electronics and PCB conformal coating
- Anti-corrosion, lubricant and functional coatings
- R&D labs and academic research
Results
Consistent Coating Quality
Repeatable coating quality across parts.
Lower Material Consumption
Reduced coating material consumption and overspray.
Improved Productivity
Automated spray paths support a more consistent production process.
Less Rework
Less rework and rejection from inconsistent coating.
Looking to Automate Your Coating Process?
Kavin Inc is based in Coimbatore, delivering turnkey robotic automation across India and Southeast Asia. Share your part and coating requirement, and our team will propose a suitable robotic spray solution.