When technology meets ecology, the benefits are magnified. So it goes in the case of VirtualPaint training, developed by the Iowa Waste ReductionCenter, in partnership with Southwest Research Institute. The concept was borne out of working with the airline industry and military, which have employed simulation training for countless years.

VirtualPaint uses state-of-the-art computer simulation and virtual reality technologies to teach and refine the techniques of paint technicians, while at the same time reducing the need for painting supplies and expensive equipment. Virtual reality software and hardware simulate real-life situations, allowing technicians to practice painting without generating any hazardous waste, emissions or even tying up a paint booth. In states such as California, where the legislature has mandated a reduction in VOCs, this system is a perfect companion to the changeover to water borne paint.

“The VirtualPaint is an essential part of any spray training process. It not only saves time and materials, but it also allows for a more comprehensive training process,” expressed Rick Klein, Sr. Research and Development Manager, University of Northern Iowa.

He described the virtual classroom, located off-campus in the Cedar Falls (Iowa) Industrial Park, as a “unique facility” with no other like it in the United States. The classroom, along with VirtualPaint, is equipped with paint booths, cure ovens and clean-up stations.

Using actual spray guns, a trainee can simulate paint application as the software records the trainee’s actions and provides a highly accurate representation of spray patterns for a variety of HVLP spray gun settings. Spray gun distance, orientation and traversal speed are displayed relative to the virtual surface, along with flow rate, air pressure and fan size. These elements combine to offer the technician all the freedom of traditional training, again without the drawbacks of costly supplies and harmful emissions. Along with these comes a time saving feature. No watching paint dry. No messy clean up required.

“This machine has unbelievable training potential, and it's cost effective as well,” explained one Army National Guard Sergeant.

After years of research and testing, the VirtualPaint is able to simulate realistic painting operations in a new and efficient way. Other variables available to technicians are brand specific coatings, primers and colors; setting target mil thickness; and determining rate of air flow – reproducing exact situations encountered on the job without even getting their hands wet.

When asked about his favorite part of the training, one painter replied, “The VirtualPaint  was incredible. It’s useful that you can spray, have the computer monitor mil thickness and then tell you where it (the spray pattern) is too heavy and too light.”

Instant visual feedback is a major asset of the virtual system. The most inexperienced painter can effectively train and, at the same time, seasoned technicians can take advantage of the system to refine their skills. Painters can evaluate their performances as they paint. When finished painting, technicians can view the accumulation mode where deviations from the targeted mil thickness are displayed through varying intensities of blue, green and red.

Now in California and Texas

Recently, VirtualPaint was introduced in California at MEGA RUST Marine Coatings and Corrosion Conference held in San Diego. This conference brings together government, military, owners, operators, shipyards, research facilities, and coatings manufacturers and suppliers to discuss issues pertinent to the preservation industries. And the VirtualPaint demonstration was very popular, with men and women of all ages trying out the system.

The system has also been demonstrated in San Francisco and has been purchased by several, soon to be announced, community colleges.

At a cost of $48,800, the technology is geared for training centers and has been approved by the painter’s union as an apprenticeship program.

Texas has VirtualPaint installed in two locations – at The Inter-American Air Forces Academy (IAAFA), currently located at Lackland Air Force Base in San Antonio, Texas, and a Saginaw RFMS shop, which just completed putting a person through the training course.