How Engineers Develop New Paint Colours


My previous truck exhibits its age. Its rusty undersides, cracked bumpers, and scratched physique bear the blemishes of 18 years on this Earth. However look deep into the Eucalyptus Mica paint and it’s nonetheless acquired that hallmark shine, its brilliance unmarred after 200,000 arduous miles. That truth is not any coincidence, relatively the results of many years of enchancment in paint science. And almost 20 years later, individuals are nonetheless working to make it higher.

On the forefront are folks like Samantha Thobe and Ibrahim Alsalahi. They’re engineers for Honda, working in Marysville, Ohio on the subsequent technology of paint colours. And in the event that they do their jobs proper—one thing that’s powerful to doubt after a considerate dialog with both of them—Honda and Acura homeowners 20 years from now will likely be as impressed as I’m in the present day.

Welcome to The Professionals, a Highway & Observe column the place we speak to the fascinating folks behind a number of the automotive business’s most fascinating jobs.

honda marysville paint shop

Paul Vernon/Honda

“My function is to take a conceptualized shade and make it manufacturable inside an automotive manufacturing setting,” Thobe, shade improvement lead on the Marysville auto plant, advised Highway & Observe. “Our design groups give you the brand new colours […] they journey the world to give you them and give you that idea […] My job is to determine how we are able to replicate this dream shade that was created in a lab with the fabric, tools, and processes made to supply nearly 230,000 items yearly on our line.”

That’s a job an order of magnitude extra difficult than making low-volume paints for high-end vehicles. A Rolls-Royce advantages from hours within the paint store, hand ending, and the promise of an proprietor who will child it. An Accord has to roll off the road in a fraction of the time, sit on an uncovered supplier lot with out consideration for weeks, and survive many years of use by somebody within the Rust Belt who treats it like an equipment. The paint must be designed from day one with this in thoughts.

honda paint shop


Honda realized this the arduous method. The legendary reliability of its Nineties and early Aughts vehicles imply all of them caught round lengthy sufficient to see the clear coats peel off their roofs and hoods, a incontrovertible fact that marred their picture as without end vehicles. Thobe’s job hinges on making a manufacturable paint that bonds nicely, is thick sufficient to outlive for years, and retains its luster.

It’s a pure function for an engineer with an eye fixed for the inventive. Thobe, who’s 25 and hails from St. Henry, Ohio, graduated from the Ohio State College for Chemical Engineering. Honda, with its massive manufacturing footprint only a brief drive from OSU’s campus, gave her a chance to flex that diploma whereas incorporating a little bit of her inventive aspect, serving to to make gorgeous colours like Tiger Eye Pearl as gorgeous in actuality because it appeared in idea pictures.

honda of america manufacturing

Paul Vernon/Honda

“In the case of chemical engineering, I simply actually preferred the specifics of the method. That you may monitor right down to the molecules and the atoms what’s occurring,” Thobe says. Ensuring all of them keep well-behaved is the important thing to creating paint that adheres nicely, arranges its crystals accurately, and displays a depth and high quality that prospects understand as costly.

Simple to fabricate and constructed to final aren’t all the time the identical, which is the place Alsalahi is available in. A 24-year-old paint sturdiness engineer from Palestine, Alsalahi’s function is in a push-and-pull relationship with Thobe’s. His job is to ensure that the paints Thobe and her staff are designing maintain as much as the salt, solar, and scrapes of the actual world.

“Sam from time to time involves me with a brand new shade,” he mentioned. “My job is to verify the shopper is completely satisfied. My job is to verify […] there aren’t any points within the subject.”

The staff paints samples of naked steel and different supplies, sending them out for exams that examine climate resistance, peel resistance, chip resistance, and extra. Utilizing these exams—which simulate over ten years of real-world put on, although Alsalahi can’t say precisely how lengthy—the staff susses out how thick the paint must be, how sizzling the paint curing ovens ought to be set to, and the way to make sure glossiness. Every shade is completely different and, opposite to instinct, thicker isn’t all the time higher.

renovation of the auto body painting operations at honda's auto plant in east liberty, ohio, will reduce co2 emissions by approximately 3,800 metric tons annually, when the projects are completed later this year


“It’s completely a stability. So once we apply thicker materials, it’s going to finally trigger us high quality points like sagging or pinholes,” he mentioned. Thicker paint, he mentioned, wants extra warmth to remedy it. Paint naturally runs away from warmth, so if you happen to dial up the thickness an excessive amount of the paint will run away from the corners, leaving these tiny pinholes that may finally develop into greater issues.

The function is a fruits of a lifetime ardour for Alsalahi.

“I’m a automotive man, I’m all the time wanting to determine what’s occurring inside a automotive. How stuff works and determining what’s inside every part makes me extra keen on my job,” he says.

After graduating with a grasp’s in mechanical engineering at Wright State, he acquired in with an automotive provider that offers with a number of producers. Honda, he says, had the hardest high quality requirements, which is what satisfied him to get in with the corporate any method doable.

“After I noticed that, I simply needed to work for Honda. I needed to be a part of the very best customary, highest high quality [manufacturer],” Alsalahi mentioned. He didn’t know he’d find yourself within the paint division till the day of, however that didn’t deter him.

“It was completely different. I needed one thing that might be a problem, that may be an on a regular basis problem. That’s why I’m sticking to it, I’m holding onto it with each of my fingers. I just like the complexity of it. Day by day we assault a fancy problem and figuring that out it and seeing the ultimate product is simply rewarding.”

Making these merchandise that final, he says, is a key a part of engineering. And if that Honda within the driveway remains to be shiny after 18 years within the solar, you higher imagine him.

honda paint engineers

Paul Vernon/Honda

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