How Mercedes Is Revolutionizing Car Design with Robot Paint Precision

Mercedes-Benz is stepping into the future of automotive painting with the introduction of ABB’s advanced PixelPaint technology at its Sindelfingen plant in Germany. This new system works alongside conventional painting methods to bring extraordinary precision and customization to high-end vehicle finishes, starting with the Mercedes-Maybach SL 680 Monogram Series.

Instead of relying on traditional masking or complex manual labor, PixelPaint applies intricate paint patterns directly onto the vehicle surface using over 1,000 individually controlled nozzles. The paint head, mounted on ABB’s IRB 5500 robot, acts much like an inkjet printer, laying down both broad color areas and fine details with exact accuracy. With help from ABB’s 3D vision system and RobotStudio software, the robot maintains a tight distance from the vehicle surface, ensuring 100 percent of the paint goes exactly where it should—no overspray, no waste.

This completely automated process eliminates the need for taping, rework, or repeat paint booth visits, making it not only cleaner and more efficient, but also more sustainable. Mercedes-Benz is using this technology to offer exclusive, made-to-order designs that would not be possible with older methods. For instance, the Mercedes-Maybach SL 680 can now feature a detailed Maybach monogram pattern in graphite grey over an obsidian black hood—a design that truly sets this model apart.

According to Mercedes-Benz’s production leaders, this marks a major milestone in high-end customization. The level of precision and repeatability achieved by PixelPaint makes sure every painted panel looks just as flawless as the next. The partnership between ABB, Mercedes-Benz, and paint supplier PPG was key to bringing this innovation to life.

As development continues, the goal is to expand PixelPaint’s capabilities even further—offering more color combinations and design options to customers seeking unique, individualized touches on their luxury vehicles.