Powder coaters today face several challenges: rising quality standards, increasing pressure to improve efficiency, and a growing shortage of skilled workers. Many companies are therefore trying to automate the coating of as many components as possible. However, complex geometries or hard-to-reach areas often still require manual finishing by experienced coaters.
Robotic systems can take on this task - provided they are easy to program, flexible to use, and can be reliably integrated into the coating process.
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Robotic systems are often considered complex and expensive. The time-consuming integration process, additional sensors and programming make it difficult for many companies - especially small and medium-sized businesses - to get started.
Robotic systems are often considered complex and expensive. The time-consuming integration process, additional sensors and programming make it difficult for many companies - especially small and medium-sized businesses - to get started.
The experience of manual coaters is particularly crucial when it comes to critical areas or touch-up sections. However, traditional robot programming makes it difficult to transfer this expertise to robots, often requiring specialized programmers.
The experience of manual coaters is particularly crucial when it comes to critical areas or touch-up sections. However, traditional robot programming makes it difficult to transfer this expertise to robots, often requiring specialized programmers.
Many coating facilities work with varying components and different geometries. Conventional robotic systems are often too inflexible for this.
Many coating facilities work with varying components and different geometries. Conventional robotic systems are often too inflexible for this.
Robotic solutions that can be used cost-effectively even for smaller batch sizes.
Robotic solutions that are intuitive to use and quick to teach.
Robotic solutions that work reliably even when components vary.
Our vision: Robotics for everyone. We make it easier to get started with automation and make robot-assisted coating accessible even to companies that handle small to medium batch sizes and have a wide variety of parts.
Together with our partner 3D.aero, we have developed intuitive robotic modules for automated powder coating systems that are specifically designed to meet the requirements of industrial coating. You can test the application under real-world conditions at our technology center in Markdorf.
The coating motion of the manual coater is recorded using a motion-tracking system and then transferred to the robot. This allows the expertise of experienced workers to be directly leveraged. As a result, robot programs can be created quickly and intuitively. This method enables rapid and practical implementation, particularly for complex components or touch-up areas.
The system automatically detects components and their positions. Based on this information, the robot adjusts its path to match the actual position of the component. This ensures reliable automation even when component positions vary. The technology is suitable for both touch-up applications and fully automated coating.
The robotic solution is fully integrated into the system control. The central WICOS PLC manages coating recipes, robot programs and component positions within a single data structure. This allows all relevant process data to be centrally controlled and monitored.
WAGNER handles the integration of the robotic solution into the entire coating system: from selecting the appropriate robot to commissioning. In addition to technical implementation, the scope of services includes consulting, project planning and the definition of clear operating procedures.
Our robotic solution lowers the barriers to entry for automated powder coating. This enables even companies with smaller batch sizes and a wide variety of components to use robotic applications cost-effectively.
Our robotic solution lowers the barriers to entry for automated powder coating. This enables even companies with smaller batch sizes and a wide variety of components to use robotic applications cost-effectively.
Even employees without in-depth programming skills can use robot-assisted coating in their daily work.
Even employees without in-depth programming skills can use robot-assisted coating in their daily work.
The robotic solution is fully integrated into the system control. Operation, process data and programs are managed centrally and are part of a comprehensive system concept.
The robotic solution is fully integrated into the system control. Operation, process data and programs are managed centrally and are part of a comprehensive system concept.
WAGNER handles consulting, planning and integration of the robotic solution as part of the overall coating system. You receive a customized solution from a single source.
WAGNER handles consulting, planning and integration of the robotic solution as part of the overall coating system. You receive a customized solution from a single source.
The modules were developed in collaboration with the robotic specialist 3D.aero and are specifically designed to meet the requirements of industrial powder coating.
The modules were developed in collaboration with the robotic specialist 3D.aero and are specifically designed to meet the requirements of industrial powder coating.
Do you have a question about robot-assisted powder coating or would you like to test our system at the technology center? Please send us your inquiry and we will get back to you as soon as possible.
The automation solutions make entry into robotics much easier and more economical. Even companies without robotics experience can use them quickly. At the same time, the technology makes it possible to use coating robots for a larger number of components and applications.
The solutions have been deliberately developed so that even companies without robotics experience can get started quickly. The technology supports complex steps such as programming and guides you safely through the entire process. We also support you right from the start - from initial orientation to tests in the technology center to commissioning.
A coating robot is always worthwhile if components have to be coated regularly, in a specified quantity or with consistent quality requirements. It is particularly economical for:
Our solution makes significantly more applications possible, as even small batches, changing components and complex shapes can be automated economically.
Our solution extends classic robotics installations and makes them much easier, faster and more flexible to use. Many complex steps, such as programming or parts recognition, run automatically. This means that robotics can also be used by companies with no previous experience - and it is suitable for many more components and applications than conventional systems.
Yes. The solution has already been fully installed and extensively tested at the WAGNER technology center in Markdorf. We are also currently working with several customers on the first reference installations in order to further test the system in productive operation. There, the new robotics solutions can be experienced for the first time in a real production environment.
WAGNER is your central point of contact for all robotics project issues. WAGNER coordinates the entire project management, from clarifying requirements to testing and commissioning. The solutions are developed in strategic partnership with 3D.aero and are initially available for the proven FANUC P‑Series coating robots (e.g. P 250 and P‑50 Painter). We currently mainly use these models, but can also integrate other robot types depending on the project
The solution is fully installed and can be experienced live at the WAGNER Technology Center in Markdorf. There you can test the functions and run through various scenarios.
Yes. At the Technology Center, you can carry out tests with your own components, including real coating tests and evaluations. This allows you to check how well the solution fits your application in a practical way.
Availability depends on the scope of your inquiry - whether it is an initial introduction, a technology presentation or a complete coating trial. We will be happy to advise you.
First, we discuss your goals, components and requirements together. We then introduce the technology and guide you step by step through the functions of the robotic system. We then test your components live on the system - including real coating, evaluation and joint assessment of the results. This gives you a transparent picture of how well the solution fits your application. This forms the basis for further tests or the start of offer engineering.
Yes, you can bring your own components and have them tested during a test appointment at the Technology Center in Markdorf. This allows you to see under real conditions how well the robotic solution fits your application. It is important that you provide us with information on the current hanging and component pick-up in advance so that we can take this into account or prepare it optimally for the robotic application.
Simply contact your regional WAGNER sales contact at or send us an inquiry using the contact form on this page. We then conduct a brief initial consultation. Depending on the project status, we will offer you a technology presentation or a test appointment at the Technology Center in Markdorf - also with your own components. We accompany you step by step and help you to specify the requirements and select the appropriate technology modules.
A special robotics day is planned in Markdorf in the second half of the year 2026. This event will give you a simple introduction to the possibilities, the state of the art and typical applications of robotics in surface coating. Please contact us if you are interested in participating.
Alternatively, please get in touch with your WAGNER sales contact. Your contact will give you an initial orientation and can present various robotics solutions to find out what makes sense for you.
Robotics and linear axes offer different but complementary savings potential:
Together, this results in significantly higher efficiency, both through savings and through qualitative and organizational effects. Let us look at your business case for the use of robotics together.
The following considerations will help you get off to an efficient start:
These points do not have to be complete at the beginning - but they help to start the joint development process more quickly and in a more targeted manner.
The robotic solutions are currently available primarily for new systems and in the first step for the FANUC P‑Series (P‑250 and P‑50 Painter). Other robot models can be tested on a project-specific basis. We examine retrofit projects individually, depending on space, hanging, accessibility and the existing control/system technology.
