3D-simulation model to predict the formation of paint film surface structures

The market appeal of consumer and technological products is strongly influenced by the appearance of the paint layer ("orange peel effect") which arises from a complex interplay of a variety of different physical processes, e.g., the statistical superposition of droplets during the spraying process, or the partial mapping of the substrate structure onto the paint film by different mechanisms. A new simulation model is presented that incorporates all the relevant processes for structure formation. Flow simulation is an important part in the physical modelling. The 3D simulation model for the first time allows for the generation of a desired paint film structure, even on different substrate surfaces like in modern multi-substrate light-weight constructions, by adjusting both paint material and process parameters in a proper way. Thus, the model can help to meet the growing demands with respect to design and reproducibility of paint film appearance.