Gantry-Based Automation for Headlight Painting

Client

A North American automotive supplier specializing in painting small auto components such as passenger car headlight housings.

Scope

Design a low-cost automated painting system to apply a uniform coat on headlight bodies, replacing a manual process while improving productivity and consistency.

Why APA Engineering

With over 10 years of Design experience in automation equipment, welding fixtures, assembly lines, workstations/work cells, and EOAT, APA Engineering was selected to deliver a practical and cost-effective alternative to conventional robotic solutions.

Challenge

The client faced multiple performance and development challenges:

• ❌ Very tight project budget, ruling out the use of industrial robots.
• ❌ We need to maintain consistent paint quality across complex component surfaces.
• ❌ Improve throughput without increasing operational costs.

Our Solution

APA developed a gantry-based painting system as a smart alternative to robots:

• ● A custom gantry mechanism enabling the X–Y movement of the spray gun for full surface coverage.
• ● Solenoid-controlled paint and air supply for precise and repeatable coating.
• ● Robust mechanical design optimized for reliability and low maintenance.
• ● Complete detailing with fabrication drawings and BOM for quick execution.

Value Delivered

• ● 10% increase in production output.
• ● Improved coating quality compared to manual painting.
• ● 3% reduction in paint consumption.
• ● Reduced operator fatigue and better workplace ergonomics.
• ● Up to 60% design cost savings, with the overall solution delivered at nearly 50% lower costthan robot-based automation.

Result

APA Engineering acted as an On-Demand Extended Design House, enabling the client to achieve automation, quality improvement, and cost efficiency—without the investment burden of robotics.