Robotic coating of large metallic chassis

Looking to boost productivity on a large metallic structure without compromising on its finish? Discover how electrostatic high-flow guns like the TRP502 and even rotary bells, offer tailored solutions to meet your performance and quality goals

Electrostatic spraying with high-flow guns like the TRP502 enables fast and efficient coverage of large surfaces, such as chassis, trailers and bus panels, while maintaining an excellent finish quality. Combined with optimized robot paths or well-trained operators, this solution dramatically shortens cycle times.

The TRP502 is a unique solution on the market, offering unmatched paint flow capacity combined with electrostatic efficiency. Unlike conventional high-flow systems that often sacrifice finish, the TRP502 delivers both speed and a smooth, consistent film build, making it ideal for manufacturers seeking high productivity without compromising visual quality.

As an alternative, electrostatic rotary bell applicators can be considered for applications requiring even higher transfer efficiency and a premium-level finish. While the overall paint flow is slightly lower, rotary bells deliver superior atomization and material savings, making them the preferred option for projects where surface appearance and transfer efficiency are the top priorities.

Yes, electrostatic spraying is highly effective for complex geometries such as chassis frames, tubular structures, and underbodies. Its natural wrap-around effect ensures better coverage of hard-to-reach areas, reduces overspray, and delivers a more uniform film build, even on angular parts.

There are, however, two specific considerations:
• Faraday cage limitation – deeply recessed or enclosed areas can resist electrostatic charge. In such cases, the solution is simple: temporarily disable the electrostatics during that phase of the application.
• Edge effect – electrostatic charge tends to concentrate on edges, leading to potential overcoating. This can be finely controlled through proper adjustment of voltage settings and optimized spray paths. In fact, controlled edge buildup can become an advantage for corrosion protection, since edges are often the most vulnerable areas on metal parts.

Once these aspects are mastered, the benefits of electrostatics—such as improved material transfer, part-attracted deposition that compensates for minor positioning variances, and high application consistency, make it a superior spraying method.

Electrostatic spraying is more than a technique, it’s a culture. Once adopted, it’s hard to go back.

Electrostatic spraying is one of the most effective ways to reduce paint consumption in metallic chassis manufacturing. By significantly improving transfer efficiency, more paint reaches the part and less is lost to overspray, resulting in lower paint usage, reduced booth maintenance, and better environmental performance, all while maintaining high-quality finishes.
Quick & efficient color-change design with Upside valves & peripherials minimize product waste during color changes and reduce downtime.

For specialized or small-batch production, Sames provides high-performance solutions such as the Cyclomix® Evo 2K dosing machine for precise, on-demand mixing with minimal waste, as well as premium manual spray guns like the Nanogun (electrostatic Airmix® or airpsray), Xcite®+ (Airmix®), and FPro (Airspray), all designed to deliver top-quality finishes with maximum paint savings.

Ultimately, the biggest driver of paint and cost savings remains the transfer efficiency of the chosen spraying technology. Whether automated or manual, Sames solutions are designed to combine precision, flexibility, and sustainability, helping you save paint without sacrificing productivity or quality.