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SprayCapture - Guided Workflow

1. Hardware Connection, Hardware Check & Maintenance, Consumables

Prepare the SprayCapture unit for first use, verify the delivered hardware, and align the team on safe handling, basic maintenance, and correct SprayTest preparation.

Delivered hardware and accessories

  • SprayCapture unit
  • Power supply
  • Ethernet cable
  • SC Unit calibration veryfication tablet
  • Optional: Elcometer 456 F Model B with straight ferrous probe
  • Optional: Magnetic stainless steel plate for paint calibrations
  • Calibration grid foils and clear foils 
  • 20 mm and 40 mm Kapton tapes
  • 10 mm Kapton cutouts (stickers)
  • Paper tape
  • Thickness rulers: 20-100 µm, 140-220 µm, 260-340 µm
  • Plastic 3 ml pipettes for paint samples

Main workflow

  • Review the delivered package and accessories.
  • Set up the SprayCapture unit in a safe location near the coating area, outside the ATEX zone.
  • Check the capturing surface
  • Use the SC Unit calibration tablet for hardware condition checks.

Articles

  • SprayCapture BELL Mk.2 - User Manual
    EN
  • SprayCapture Unit Calibration Verification
    EN

2. Commissioning, Connection Settings & Unit Communication

Set up the user PC, network connection, HTTPS communication, user access, and application preferences before the first real capturing session.

Main workflow

  • Connect the SprayCapture unit to power.
  • Connect the SprayCapture unit via Ethernet.
  • Prepare internet access on the user PC.
  • Check SprayCapture unit network configuration
  • Configure the dedicated network card.
  • Log in to the SprayVision application.
  • Add the SprayCapture unit in settings.
  • Load or verify the HTTPS certificate.
  • Capture an empty sample to test communication and transparency of the capturing surface across all required light sources.
  • Set the preferred interface language in settings.

Articles

  • SW & HW requirements list
    EN
  • Account Credentials
    EN
  • Accessing Unit Information via Display
    EN
  • Network Card Settings
    EN
  • Connection and setup of the SprayCapture unit network schematic
    EN
  • Explanation of Unit–App Communication Principles and Security Setup
    EN
  • HTTPS Certificate - Update via SprayCapture
    EN
  • Certificate *.pem File Installation
    EN
  • Hardware Connection Issues - Chromium engine version 142.0.7444.60 and above
    EN
  • How to Change Language in SprayCapture & SprayBrush
    EN
  • SSO – Single Sign-On
    EN
  • SprayCapture access, connectivity, license, SprayCapture calibration check, and certificate issues
    EN
  • Help Button
    EN

3. Capturing Samples & Working with the Database

Capture samples, store them in the database, assign calibrations, edit sample properties, and process larger sample series efficiently.

Main workflow

  • Place a clean foil on a flat surface close to the booth.
  • Prepare the first static and dynamic SprayTests.
  • Use production-relevant applicator settings.
  • Capture static patterns first.
  • Capture at least two slightly different static patterns for Process Control training.
  • Capture dynamic patterns with production-relevant robot movement and applicator settings.
  • For dynamic patterns, move through the shorter side of the pattern and choose portrait orientation before capturing.
  • Assign the correct paint calibration to calibrated samples.
  • Evaluate the result and edit local shortcomings when required.

Articles

  • Spraytest Creation Methodology
    EN, ES
  • Samples of Dynamic and Static SprayTests
    EN, FR, ES
  • Database
    EN, DE, FR, ES
  • Pattern Analysis - Workflow
    EN, DE
  • New Pattern Editor - 1.18.53
    EN, DE
  • Batch Processing - 1.18.53
    EN, FR, ES

4. Paint Calibration

Create a paint calibration so SprayCapture can evaluate coating thickness in µm or mils instead of raw intensity units.

Main workflow

  • Select the paint to be calibrated.
  • Define the calibration method: drawdown method, dynamic spray method, high-opacity workflow, or soft paint workflow.
  • Prepare approximately 50 ml of paint for the drawdown method.
  • Prepare paint quantity according to the customer coating system for the dynamic spray method.
  • Keep the calibration foil in a horizontal position until dry.
  • Verify the ferromagnetic measurement device according to the gauge supplier rules.
  • Capture the calibration foil.
  • Cure the calibration foil.
  • Recommended curing reference: 115 °C / 239 °F until dry.
  • Create the calibration curve from the lowest to the highest thickness.
  • Assign the new calibration to the calibration foil.
  • Cross-check SprayCapture results against Permascope or the selected reference method.

Articles

  • Calibration Methodology - Light Sources
    EN, ES
  • Quick overview of the paint calibrations procedure (cheat sheet)
    EN
  • Full guide: How to prepare a sprayed calibration foil Module V2 (video)
    EN
  • How to spray a calibration foil only (video)
    EN
  • Creating Dynamic Calibration
    EN, ES
  • Full Guide: Preparing a Drawdown Calibration Foil – Calibration Module V2
    EN
  • Paint Calibration Module V2 (2026)
    EN, ES
  • Paint Calibration Module V1
    EN, ES
  • Calibration of High Opacity Paints
    EN, ES
  • Soft Paint Calibration
    EN, ES

5. Process Control

Monitor applicator output, compare static patterns against a defined gold standard, evaluate process stability, and track changes over time directly from the booth workflow.

Main workflow

  • Create a new Process Control project in the project manager.
  • Define a representative static pattern as the gold standard.
  • Capture another static pattern and evaluate the deviation against the gold standard.
  • Set up cabins, robots, or booth positions to speed up repeated measurements.
  • Capture images through robot-based or zone-based layouts.
  • Evaluate process statistics.
  • Create Process Control widgets on the homepage.
  • Monitor applicator condition and repeatability over time.

Articles

  • Process Control - Metrics
    EN, DE, ES
  • Process Control - Robots
    EN, DE, ES
  • Process Control – Robot Cabin (video)
    EN
  • Process Control - Droplet Density Metric - 1.18.53
    EN, DE

  • Process Control - Statistics
    EN

6. Thickness Area Mapping

Evaluate coating distribution across a larger area or a real part zone for homogeneity checks, laboratory comparison, and validation of coating thickness in selected areas.

Main workflow

  • Attach clear foils, Kapton foils, or Kapton cutouts to a scrap part.
  • Choose areas relevant for the customer, laboratory, or process engineering team.
  • Paint one layer using the calibrated paint.
  • Remove the painted sample from the part.
  • Place the sample on a clean foil.
  • Capture the sample with the correct calibration via the capturing menu.
  • Open the captured sample in SprayCapture.
  • Evaluate homogeneity and resulting material thickness.
  • Compare SprayCapture thickness measurement against laboratory measurement when available.

Articles

  • Thickness Area Mapping for Thickness Evaluation
    EN

7. Brush Development

Use captured dynamic patterns and process parameters to support brush development decisions, compare candidate outputs, evaluate repeatability, and link every sample with real process conditions.

Main workflow

  • Capture static and dynamic outputs from candidate applicator settings.
  • Evaluate dynamic patterns with SB50 and brush profile tools.
  • Compare multiple outputs side by side.
  • Evaluate differences in shape, size, height, angle, and volume.
  • Record process parameters or brush table values for every captured sample.
  • Use transfer efficiency when TE% by volume is required for brush development or optimization decisions.

Articles

  • How to Use the Comparison Module
    EN,  FR
  • Application Profile - Link Process Data to Captured Images for Full Traceability
    EN, DE, ES
  • Deep Analysis - Transfer Efficiency
    EN

8. Deep Analysis

Use Deep Analysis for a detailed view of paint distribution quality, droplet behavior, contamination, transfer efficiency, robot-related timing effects, and changes over time.

Main workflow

  • Analyze droplet distribution using analytical data and histograms.
  • Analyze contamination type, distribution, and possible origin.
  • Align captured data with robot and conveyor motion or timing.
  • Visualize sample changes over time during long-term testing or repeated measurements.

Articles

  • Droplet Analysis
    EN
  • Contamination Analysis
    EN
  • Robot Synchronization
    EN
  • Timelapse
    EN

9. Export Data & Share Best Results Across the Company

Document results, share them with customers, archive them internally, and reuse validated outputs across other teams, plants, and key users.

Main workflow

  • Select the most relevant analyzed samples.
  • Export evaluated data and results into reports.
  • Use reports for customer communication, internal validation, or troubleshooting documentation.
  • Store validated patterns, application profiles, or selected results in the catalog.
  • Use the catalog to support knowledge sharing across teams or plants.
  • Keep best-practice examples available for future Process Control, brush development, and training.

Articles

  • How to Use the Protocol Creator
    EN, FR
  • Catalog / User Catalog Management / Admin Catalog Management
    EN