VW 96185-1 Painting - Evaluation of Surface Defects on Painted Bodies and Attachments

The “ VW 96185-1 Painting - Assessment of surface defects in painted bodies and attachments” standard, developed by the Volkswagen automotive company , applies to Porsche AG. The test is performed according to the PPV 4021 standard.

Unacceptable types of surface defects on painted bodies and attachments include:

• Spray mist
• Swelling
• Vapor
• Pubescence
• Spray shadows
• Holograms

Countable defects are classified according to the following defect sizes (diameter including dye accumulation due to capillary action):

• Small to 1,0 mm
• 1,0 mm to 1,5 mm medium
• 1,5 mm to 2,0 mm large
• Defects greater than 2,0 mm are not allowed

If any of the criteria listed in the “Test criteria” table given in the standard are not met, the test result is considered non-compliant.

The limiting sample tables for paint defect characteristics provided in the standard are used to assess the severity of defects on a vehicle. In practice, the sample sheet is placed over the entire surface to be evaluated. The evaluation is performed at a 90-degree angle to the surface. The tables indicate the limiting value.

The tables are stored in an overview table showing a vehicle silhouette and zones for the model types tested. The boundary sample table is reviewed annually by the Product Inspection and Transport Quality Department and documented with an inspection tag. The boundary sample tables for paint defect characteristics are displayed at all relevant inspection locations.

The boundary sample tables are organized as follows:

• Region 1 Boundary sample tables:
  • Red with dirt
  • Silver containing dirt
  • Painted black dot
  • Red paint texture
  • Silver paint texture
  • White paint texture
  • Red sandpaper marks
  • Silver sandpaper marks
  • Red silicon craters
  • Silver painted PVC dirt
  • Silver sanding defects / sanding grooves
• Region 2 Boundary sample tables:
  • Red with dirt
  • Silver containing dirt
  • Silver PVC dirt, painted on top
  • Red paint texture
  • Silver paint texture
  • Red sandpaper marks
  • Silver sandpaper marks
  • White paint texture
  • Red PVC dirt painted
  • Red sanding defects / sanding grooves
• Region 3 Boundary sample tables:
  • Red with dirt
  • Silver containing dirt
  • Silver PVC dirt, painted on
  • Paint texture, red
  • Paint texture, silver
  • PVC texture replacement, silver
  • PVC waviness, PVC edge, silver
  • PVC texture change, red
  • PVC waviness, PVC edge, red
  • Silver sanding defects / sanding

In short, VW 96185-1 is a Volkswagen Group standard that outlines procedures and criteria for assessing surface defects on painted vehicle body parts. This standard is crucial for ensuring the visual quality and durability of painted surfaces, which are crucial for both aesthetic appeal and corrosion protection.

This standard provides detailed guidelines for identifying and evaluating various surface defects, such as scratches, dents, inclusions, and paint marks. It establishes acceptable limits for these defects, ensuring consistency in quality control throughout the manufacturing and repair processes.

By complying with the VW 96185-1 standard, manufacturers and service providers can maintain the high-quality finish expected of Volkswagen vehicles, ensuring customer satisfaction and brand integrity.

The VW 96185-1 standard, published by the Volkswagen Group, provides comprehensive guidelines for evaluating surface defects on painted vehicle body parts. While the full document is proprietary and not publicly available, it outlines specific test methods and acceptance criteria to ensure the visual quality and durability of painted surfaces.

The test methods defined in the VW 96185-1 standard generally refer to established test procedures for evaluating various aspects of painted surfaces. These may include:

• Visual inspection: Evaluating the painted surface under standardized lighting conditions to identify defects such as scratches, dents, inclusions, and paint marks.
• Cross-cut adhesion test (DIN EN ISO 2409): Evaluating the adhesion of a paint coating by creating a cross-hatch pattern and applying adhesive tape to determine the resistance of the coating to peeling.
• Scratch resistance testing: Determining the resistance of the coating to scratching under specified loads using instruments such as the Erichsen hardness tester pen.
• Gloss measurement (DIN 67530): Measuring the gloss level to ensure that the painted surface meets the specified requirements.
• Colorimetric evaluation (DIN 6174): Evaluation of color differences using the CIELAB color space to ensure color consistency in painted parts.
• Environmental resistance tests: Subjecting painted parts to various environmental conditions, such as temperature and humidity cycles, to evaluate the durability of the paint under real-world conditions.

Compliance with the VW 96185-1 standard ensures that painted vehicle body parts meet Volkswagen's stringent quality requirements. By following specified testing methods and acceptance criteria, manufacturers can maintain the aesthetic appeal and protective functions of painted surfaces, thus preserving brand integrity and customer satisfaction.

This standard is particularly important for the quality control of painted surfaces on Volkswagen Group vehicles. The importance of this standard is based on the following key factors:

• 1. Standardizing surface quality: Systematically determines how to evaluate defects such as scratches, dents, dust, drips, and orange peel effects on the paint surface. This ensures consistency across different production facilities and minimizes subjective evaluations.
• Aesthetics and brand perception: The exterior appearance of Volkswagen vehicles directly impacts the brand's perception of premium. Standardization helps prevent visible flaws, contributing to a strong first impression on customers.
• Corrosion and durability: Imperfectly painted surfaces can lead to rust and under-paint corrosion over time. This standard ensures the quality of the protective paint layer.
• Production and supplier quality assurance: Volkswagen requires original equipment manufacturers and supplier manufacturers to produce in accordance with its quality criteria. Audits evaluate against this standard. This ensures that suppliers maintain control over their quality processes.
• Defining quality control processes: This standard defines which tests to be performed (e.g., visual inspection, scratch testing, gloss measurement) and which errors are acceptable. This creates a clear framework for quality control departments.

Our organization, which has been supporting businesses across all sectors for years through a wide range of testing, measurement, analysis, and evaluation activities, has a strong team of employees who closely follow global developments in science and technology and are constantly improving themselves. In this context, we also provide testing services in accordance with the "VW 96185-1 Painting - Evaluation of surface defects on painted bodies and attachments" standard.