Case Study: Audi achieves flawless two-tone finish and reduced rework with Materialise RapidFit+ jigs

A Perfect finish for audi A1

Audi needed a flawless bicolor finish for the A1 but found masking and repainting the contrast areas—especially trunks and doors—caused difficult edges and occasional door/body collisions that required time-consuming manual refinishing. To solve this, Audi turned to Materialise and its RapidFit+ jigs to ensure precise masking and protection during the second paint stage.

Materialise adapted RapidFit+ designs for soft tooling so multiples could be made cost‑effectively, printed the jigs in yellow for better contrast, and built a low‑volume production line: six large and three small trunk jigs, and three of each door jig. The jigs use magnets for quick attachment and FDM‑printed integrated springs to lock between hinges, preventing collisions and rework, delivering consistent, production-ready paint edges and repeatable, on-demand replacements from Materialise.

Audi