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The primary coating layer that inhibits salt spray induced corrosion on vehicle bodies is electrocoat. The application of electrocoat involves the electrodeposition of a polymer film on all metallic components of the vehicle body after body construction. Particularly challenging in the electrocoat process is the deposition of the coating in recessed areas of the vehicle due to material and electrical current access constraints to those regions. Currently the verification of correct electrocoat coverage requires the use of costly tear-down prototypes. A simulation tool, called EPD, has been developed that predicts the electrocoat coverage on the full vehicle body. The tool allows engineers to identify areas where there may be issues with electrocoat coverage and to see the effect of vehicle design or process modifications on coverage. A challenge in the development of any simulation tool is computational speed.