Applications of compressed air in automobile manufacturing

By Staff Report July 9, 2025 6:16 pm IST

The automotive sector uses compressed air for manufacturing, assembly lines and functions at the body shop. On our way to work, we regularly inflate the tyres of the vehicle we drive; this is indeed an application of compressed air. However, it doesn’t stop there; it is also used in the making of tyres, seats, and automotive assembly lines, as well as in robotic applications, among other uses. Its adaptability has made it a vital tool for operational safety and efficiency and simplifies production with the use of dependable and effective compressed air equipment.

Compressed air tools: Pneumatic tools like power wrenches, air rachets, air rivets, air hammers, drills, sanders, and pneumatic nailing are all powered by compressed air systems. They are used in automotive assembly lines for their consistent performance, safety, compact design, and ability to generate sustained torque and speed without producing excessive heat or requiring complicated electrical systems.

Painting and body finish: A superior quality paint is expected to give a car a premium look, which it deserves. To guarantee a flawless mirror surface and a consistent, dependable paint spray for door panels, side panels, roof pieces, and other auto body parts, compressed air is employed in spray painting applications. Chicago Pneumatic Compressors offers a comprehensive solution for compressed air, including add-on filters and refrigerated air dryers, which can reduce the compressed air temperature to a point where moisture condensation occurs. This can help remove moisture and minimise contaminants like dirt and oil within the stream of air.

Laser, Plasma-Cutting and welding applications: Compressed air is used in Laser and plasma-cutting processes for car manufacturing, where it acts as the primary or secondary gas to generate high-pressure and high-temperature plasma jets. In certain welding operations, compressed air is used to shield the weld and improve weld seam quality.

Tyre Inflation: Right from a petrol pump to a puncture shop, we all have seen a piston or a screw compressor used for inflating air in tires to maintain sufficient pressure for a smooth drive.

Pneumatic Robotic assembly lines and material handling and holding: Lean and flexible manufacturing and assembly systems are designed to boost the productivity of assembly lines. These robotic assembly systems lift heavy auto parts and automobile body components via vertical lifts or conveyor systems. These automated systems are pneumatically operated and powered by compressed air systems.

Factors to consider while selecting a compressor for automobile manufacturing

Compressors orbit almost every application in the world of automobile manufacturing. Selecting a compressed air solution requires key considerations, as it contributes to saving power, adding profits to business, leading to faster returns on investments, and reducing the carbon footprint for a better and greener tomorrow.

Air Requirement:  A compressed air installation should be based on the required FAD (CFM), never based on compressor power. Remember that with every CFM, the power requirement increases, along with the capital and running costs. Using the load factor and simultaneous usage factor is very important, as not all machines are loaded at 100% and used simultaneously. Chicago Pneumatic can help users know their optimal air requirements. 

Working Pressure: Energy expenses rise by approximately 7% for every bar increase in working pressure. Thus, choosing the appropriate compressor working pressure is crucial for an effective installation.

Power Efficiency: Compressors equipped with a variable frequency drive, whose speed is controlled electronically, maintain the compressed air at a constant pressure within a very tight range and offer outstanding opportunities for energy savings, as power consumption is adapted to the flow requirement. At Chicago Pneumatic Compressors, we have tools and software like iTrack & Airchitect to determine the right usage of existing installations and simulate the energy-saving reports with the help of live recorded data. These tools help with existing installations, provide efficient energy management and design, and simulate, size, and configure a new installation setup.

Chicago Pneumatics also considers several important factors, such as air quality, noise levels, cost (both upfront and over time), and maintenance, when designing the best solution.

To know more, write on:customer.care@cp.com