Discover our complete solutions portfolio covering Cathodic Protection and Corrosion management - PCB design and plating - Functional and decorative plating - Electrocoating - Acoustics
Elsyca V-PIMS
A revolution in digital PIMS combining Pipeline Corrosion Integrity Management System (PIMS) and computational modeling capabilities
Elsyca IRIS
Deep analysis of AC threats supporting efficient mitigation systems computer-aided design
Elsyca CatPro
Graphical simulation platform for cathodic protection and DC stray current analysis of pipeline networks
Elsyca CPManager
3D CAD-based software simulation platform for the computer-aided design and analysis of cathodic protection installations
Elsyca ACTA
Unique solution offering accurate, disambiguated, and tailored risk ranking report of pipeline networks
Elsyca PlatingManager
Leverage a digital twin of your plating line to predict plating performance and increase manufacturing capacity
Elsyca PCBBalance
The world’s only PCB DFM software that applies automated and optimized copper balancing to your PCB design and panel layout.
Elsyca PCBPlate
State-of-the-art graphical simulation platform for enhancing the plating performance of your PCB panel and pattern plating processes.
Elsyca ECoatMaster
CAD independent software platform for the simulation of the automotive electrocoating process of a body-in-white (BIW).
Elsyca EPOS
Simulate the performances of electropolishing processes based on a virtual mock-up of the electropolishing cell.
Elsyca AnodizingManager
State-of-the-art graphical simulation platform for analyzing the production performance and quality of anodizing processes.
Elsyca CorrosionMaster
CorrosionMaster identifies corrosion hot spots and predicts corrosion rates, enabling engineers to look at alternative material combinations and/or coating systems, or investigate corrosion-mitigating measures.
Elsyca LeakageMaster
Improve vehicles interior acoustic comfort by performing upfront virtual smoke tests.
Elsyca MeshingMaster
Automatically creates meshes for a variety of applications such as acoustics, CFD, thermal analysis, etc
Elsyca XPlorer
Interactive simulation results viewer for Finite Elements results
Elsyca XPlorer3D
Analyze, Understand and Get Immersed in your results

How Elsyca ECoatMaster accurately simulates the e-coat process

The identification of the surface risk areas and validation of the impact of design modifications and/or changing process parameters have never been that simple.

How Elsyca ECoatMaster accurately simulates the e-coat process

Also known as electrodeposited paint coating, or electrophoretic deposition, e-coating is the most effective method for applying a high-quality, uniform finish. Its inherent ability to provide full  coverage of the deposited surfaces, to achieve lower paint layer thickness specifications and to withstand the salt spray test requirements, makes e-coating a valuable process for the automotive industry.

Context & Challenges

Around the world, automotive OEMs use e-coating in order to provide their products with a superior, durable, lasting surface finish. The process produces little or no hazardous air pollutants and is compliant with various health regulations but also minimizes material and energy waste compared to liquid spray or powder coating processes.

Despite its numerous advantages, the control of e-coating process performances remains a challenging task as many parameters play an important role in the final deposit quality. 

E-coating relies on electrical paint particles that are deposited to coat bodies. The final paint deposit thickness on parts is driven by many parameters such as the amount of voltage that is applied, the body geometry, the coating bath dimensions or the anodes position, shape and dimensions. The body trajectory, speed and orientation in the bath are also parameters to be  considered to achieve final high quality deposit. As the vehicle body in white (BIW) structure enters the bath, air entrapment can occur in the inner structure as well as air gas bubbles can form along the surface of the body. Both phenomena can be an issue as they block the paint deposit on the metal surface.

In case any of these parameters will be off or unadjusted properly, a risk of poor coating quality always exists leading to further wet tests in order to assess what went wrong and how to further improve it. This experimental way of addressing and solving issues is not only time-consuming but also requires additional material and financial sources to be spent.

Elsyca’s solution 

Elsyca ECoatMaster accurately simulates the entire e-coat process and allows engineers to apprehend the effects of all e-coat parameters on the final deposit quality. Based on a digital twin approach where the entire e-coating line infrastructure, vehicle BIW and e-coating program parameters are considered, Elsyca ECoatMaster predicts the current density and deposited paint layer thickness on the car structure. 

The identification of over- or under-deposited areas and validation of BIW design modifications, process parameters or tank properties have never been that simple.

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