At Eleven Dynamics, we work with automation systems that need to understand what is actually in front of the robot. In robotic spraying, this becomes especially relevant when the real component is slightly shifted, deformed, or different from the nominal geometry used to create the original robot path.
Robotic spraying uses an industrial robot to move a spray tool across a component while controlling position, orientation, speed, and distance to the surface. This can be used for applications such as automotive body parts, large vehicle components, aerospace structures, composite parts, or other surfaces that require a consistent automated spraying process.
Most robotic spraying systems follow a predefined trajectory based on CAD data, offline programming, or taught positions. This works well when every part arrives exactly as expected, but variations in part position or geometry can change the distance and angle between the spray tool and the real surface.
With 3D metrology, the component can be measured before spraying so the system understands its actual position and geometry. This information can then be used to adjust the robot trajectory, allowing the spraying process to follow the real surface instead of relying only on nominal data.
The process starts by scanning or localizing the component before spraying. The measured geometry is compared with the digital model, relevant differences are identified, and the robot trajectory is adapted before execution. In simple terms: scan, understand, adapt, spray.
An adaptive spraying cell connects 3D measurement, robotics, digital models, path planning, simulation, and automation software. The key challenge is turning measurement data into a safe and usable robot path while considering tool orientation, reachability, collisions, and production cycle time.
Using real measurement data can reduce the dependency on perfect part positioning and make the spraying process more flexible when working with large, complex, or varying components. It can also help maintain a more consistent relationship between the spray tool and the actual surface throughout the process.
The next step in robotic spraying is not simply making robots more precise, but giving them better information about the real component before they start. By connecting 3D metrology directly with automation, spraying systems can move from fixed trajectories toward processes that adapt to real production conditions.
