Digital Support for Manual Coating

Bridging Craftsmanship and Data-Driven Analysis

Manual coating is one of the most demanding disciplines in industrial surface engineering. Especially for complex geometries and non-standardized processes, it remains irreplaceable – even in the era of automation and artificial intelligence.

Experienced applicators operate with a level of precision comparable to artists. They control not only the material properties of coatings but also the spatial distribution of the spray pattern to achieve consistent, high-quality surfaces.

Even with high-end spray guns from brands like SATA or ANEST IWATA, the decisive factor lies in mastering a highly complex parameter space. Each user develops individual techniques and motion patterns – making manual coating both a science and a craft.

What is SprayConeAI®?

SprayConeAI® is an open-access web application designed to bring digital analysis into manual coating processes.

It enables users to:

Document spray patterns
Analyze coating distribution
Transform 2D spray images into 3D representations
Correlate spray behavior with coating results

Originally developed through student research projects at aiQ, SprayConeAI® focuses on simplicity, accessibility, and practical usability, especially in repair and workshop environments where traditional measurement systems are impractical.

How It Works

Using SprayConeAI® is simple and requires no specialized hardware:

Visit SprayConeAI.com
Capture a spray pattern or upload an image
Add optional comments about your setup
Use a calibration sticker (optional)
Process the image and download results

The application works on desktop and mobile devices, enabling flexible use directly in real-world environments.

Key Features

No data storage on external servers
Local image processing on your device
Privacy-friendly system architecture
Easy-to-use interface for industrial and workshop settings
Optional calibration for physical scaling

Scientific Background

SprayConeAI® is not just a tool—it is based on established scientific measurement principles.

The concept originates from research published in 2016 by Schaefer [1], introducing the spray matrix approach.

Spray Matrix Concept

Based on the TSTOF measurement method
Measures:
- Droplet size
- Droplet velocity
- Droplet number density
Enables spatially resolved analysis across the entire spray cone

By scanning the spray field, a complete characterization of droplet distribution is achieved.

From Measurement to Application

The classical measurement results can be directly correlated with:

Painted surfaces
Coating thickness distribution
Spray geometry

SprayConeAI® extends this approach by enabling:

Analysis of scanned transparent foils
Estimation of coating thickness
Visualization of spray cone structures

This creates a direct link between:
Droplet dynamics → Spray pattern → Final coating quality

Use Case: Practical Environments

SprayConeAI® is particularly valuable where:

Time is limited
Space is restricted
Complex measurement systems are unavailable

Typical applications include:

Repair coating
Process optimization
Training and documentation
Quality assurance

Development & Future Outlook

SprayConeAI® is continuously evolving.

Upcoming features include:

Detection of donut-shaped spray patterns
Surface property characterization
Color analysis and recognition
Advanced AI-driven spray diagnostics

These developments aim to further enhance the understanding and optimization of spray processes.

Conclusion

SprayConeAI® combines:

Traditional craftsmanship
Modern image processing
Scientific measurement principles

It provides a low-threshold, powerful tool for improving manual coating processes—without replacing the expertise and intuition of skilled applicators.

Stay Updated

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References

[1] Schäfer, W., Rosenkranz, S., Brinckmann, F., & Tropea, C. (2016). Analysis of pneumatic atomizer spray profiles. Particuology, 29, 80–85. https://doi.org/10.1016/j.partic.2015.12.002

[2] Schaefer, W., Li, L., Stegmann, P., & Terada, M. (2026). Technical report on the TSTOF measurement method: Technical basics, historical development, and comparison with other laser-based measurement methods. Photonics, 13(1), 56. https://doi.org/10.3390/photonics13010056