Corrosion protection in the automotive industry—efficient, sustainable, and easily integrated
Protective solutions for modern vehicle designs
Corrosion is one of the main threats to a vehicle’s longevity—invisible, yet often with serious consequences. That is why corrosion protection has played a key role in the automotive industry for decades. Modern vehicles consist of complex body structures, lightweight components, and electronic parts—all of which require well-designed and effective rust protection.
PFINDER offers customizable solutions for corrosion protection in the automotive industry—efficient, sustainable, and perfectly integrable into existing production lines. Our focus is on automated, process-integrated coating systems that provide reliable protection against corrosion without disrupting the production process.
Our customizable solutions for corrosion protection in the automotive industry increase efficiency. We demonstrated this during the conversion of a flood wax line for a Brazilian customer. Additionally, our products contribute to improved sustainability by reducing process temperatures and, consequently, energy consumption.
Why is corrosion protection so important in the automotive industry?
Corrosion is caused by chemical reactions in which metallic materials react with oxygen and moisture. Areas that are difficult to access, such as cavities, overlaps, seams, or formed sheet metal, where condensation or splash water collects, are particularly problematic. If not protected against corrosion, this can jeopardize the structural integrity of the vehicle—with consequences for safety, warranty claims, and customer satisfaction.
The demands placed on modern corrosion protection are constantly increasing:
- Reduction in vehicle weight → thinner sheet metal
- Hybrid construction involving combinations of different materials, e.g., aluminum and galvanized steel
- High demands on sustainability and VOC reduction
- Integration into synchronized, highly automated production processes
All these factors make it necessary to tailor protective coatings precisely to the respective application—functionally, material-compatibly, and economically.
An overview of the most important technologies
PFINDER offers a wide range of corrosion protection products for the automotive industry that can be flexibly combined and customized. Depending on the application, different technologies are used:
Cavity wax
Underbody protection
Varnish-like coatings
Temporary corrosion protection
Application Spotlight: Flooding or Spraying
Fully automated application is a key factor in the success of corrosion protection in the automotive industry. It ensures consistent quality, high reproducibility, and seamless integration into synchronized production lines.
PFINDER solutions are optimized for various application methods:
Here, the corrosion inhibitor is applied precisely through specially shaped nozzles—usually via robots—into the corresponding cavities or onto the underbodies. Targeted flow technology allows for precise control of product volume and distribution.
Advantages:
- Minimal material consumption due to precise dosing
- Can be customized for specific body types
- Can be easily integrated into synchronized production lines
For medium and small production runs, semi-automatic spray systems are used, which can be stationary or mobile—for example, with lances, spray guns, or rotating spray heads with predefined application rates.
Advantages:
- Flexible adaptation to different vehicles
- Lower investment costs
- Defined material volume
For small-batch production, during the ramp-up of production runs, or even for special applications, materials can also be applied manually using spray guns, cartridges, or even brushes and sponges:
Advantages:
- Extremely flexible for the range of applications
- Material quantities can be adjusted
- Easy material changeover possible
During the flooding process, the cavity system of a body panel is completely filled with the corrosion inhibitor. This allows the solution to penetrate even into nooks and crannies, overlapping panels, and hard-to-reach crevices. The excess material is then drained off.
Advantages:
- Complete coating of complex geometries
- Ideal for large-scale production runs with consistent body structure
- Very short cycle times with a large coating area
Typical applications in vehicle production
PFINDER products are used at several stages of vehicle manufacturing:
- After the body-in-white phase: cavity protection and preparation
- After painting: Application of underbody protection, additional coatings
- In special production lines: e.g., for e-mobility projects or HV battery housings
- In export logistics areas: Temporary protection for vehicles en route to the customer
The individual measures are precisely tailored to the OEM production concept and the planned service life.
Sustainable corrosion protection: Fewer emissions, greater effectiveness
Modern corrosion inhibitors must not only be effective, but also sustainable. That is why PFINDER relies on:
OEM Approvals & Practical Examples
Our products are approved for use in numerous automotive plants worldwide, in accordance with international standards. Whether European premium manufacturers or global volume suppliers—PFINDER corrosion protection systems are an integral part of efficient and sustainable vehicle production.
Examples of applications:
- HV battery housings with paint-like exterior coating
- Standard robotic application of cavity wax in doors and beams
- Underbody coating via nozzle in SUV production lines
- Temporary rust protection for vehicle components in CKD shipments
Korrosionsschutz im Hohlraum
Hohlraumstrukturen von Fahrzeugkarosserien bilden effiziente Konstruktionen mit hoher Steifigkeit und Crashschutzrelevanz und daher müssen sie besonders bei Feuchtigkeit vor Korrosion geschützt werden.Surface protection for battery systems | Corrosion protection for battery systems
Protective systems for surfaces in battery systems against corrosion, moisture, and mechanical stress.Underbody Protection for Vehicles | Corrosion Protection & Stone Chip Protection
The underbody is the part of a vehicle most exposed to the elements and stone chips, and therefore requires long-lasting, flexible protection against corrosion.
Corrosion protection as an integral part of the automotive industry
The demands for corrosion protection in the automotive industry are constantly increasing—driven by new vehicle designs, e-mobility, sustainability goals, and complex manufacturing processes. With its broad product and application portfolio, PFINDER delivers flexible, OEM-proven solutions that integrate seamlessly.
Our protective coatings ensure that vehicle parts are permanently protected against corrosion—automatically, cost-effectively, and with future-proofing.
Your contact person
71032 Böblingen