Guide to Airless Spray Painting
Airless spray painting is a method of applying paint or coatings by using high fluid pressure to force the material through a small spray tip, where it atomizes into fine droplets without the use of compressed air. The resulting spray pattern allows paint and coatings to be applied quickly and evenly across a wide range of surfaces.
Unlike conventional air spray systems that use compressed air to atomize the coating, an airless paint sprayer relies on fluid pressure generated by the pump. The pump, pressure setting and spray tip work together to control material flow, atomization and the resulting spray pattern. For professional painters and coating contractors, airless paint spraying is widely used for residential, commercial and industrial applications because it combines high production capability with the ability to apply many different types of coatings.
How Does Airless Spray Painting Work?
An airless paint sprayer draws paint or coating material from its container and uses a pump to pressurize it. The material travels through a high-pressure hose to the spray gun. When the gun is triggered, the pressurized coating is forced through the small opening in the airless spray tip, where the fluid stream breaks into small droplets. This process is called atomization.
The basic airless spray painting process can be summarized as:
Because fluid pressure rather than compressed air is used to atomize the coating, a separate compressed-air supply is not required for the atomization process.
What Are the Main Parts of an Airless Paint Sprayer?
Although equipment designs and capabilities vary, a professional airless paint spraying system generally relies on several primary components working together:
- Pump: Draws the coating from its container and pressurizes it.
- Motor or power source: Provides the power needed to operate the pump.
- Pressure control: Allows operating pressure to be adjusted for the coating, tip and application.
- High-pressure hose: Carries pressurized coating from the pump to the spray gun.
- Spray gun: Controls when coating is released.
- Spray tip: Helps determine spray-pattern width and material flow.
- Tip guard: Helps properly position the spray tip while providing an important protective function.
Each component contributes to the performance of the overall airless spray system. The pump must provide sufficient output for the application, while pressure and tip selection must be appropriate for the material being sprayed.
What Does the Spray Tip Do in Airless Paint Spraying?
The airless spray tip plays a major role in controlling how coating leaves the spray gun. Airless tips are available in different fan widths and orifice sizes. Fan width affects the width of the spray pattern, while the orifice size affects the amount of material that can pass through the tip.
For example, a 517 airless spray tip generally indicates an approximately 10-inch fan pattern at the specified spraying distance and a .017-inch orifice. Actual spray performance can vary based on the coating, operating pressure, tip condition and spraying technique. Selecting the appropriate tip helps achieve proper atomization and a consistent spray pattern without using more pressure than necessary.
Learn more about airless spray tip sizes and how to select the correct tip for different coatings.
Why Do Professional Painters Use Airless Paint Spraying?
One of the primary advantages of airless spray painting is production speed. A properly selected professional system can apply coatings efficiently across large surface areas, making airless equipment well suited to many high-production painting and coating projects.
Professional airless equipment is also versatile. Depending on the sprayer’s capabilities and the coating manufacturer’s application requirements, an airless system may be used with materials ranging from stains and architectural paints to primers and heavier protective coatings.
Advantages of airless spraying can include:
- Fast application across large surface areas
- Consistent coating delivery
- Ability to spray a range of coating viscosities
- Adjustable pressure for different applications
- Multiple spray-tip sizes and fan patterns
- Long hose configurations for larger job sites
- Efficient application to textured and irregular surfaces
The sprayer, tip and operating pressure should always be matched to the coating and application rather than using the same setup for every project.
What Can You Spray With an Airless Paint Sprayer?
Professional airless paint sprayers can apply a broad range of paints and coatings, although compatibility depends on the sprayer’s capabilities, tip size and coating specifications.
Common materials may include:
- Interior and exterior latex paints
- Acrylic coatings
- Primers
- Enamels
- Stains and sealers
- Elastomeric coatings
- High-build coatings
- Certain industrial and protective coatings
Higher-viscosity and high-solids materials may require equipment capable of supporting larger tip sizes and higher material output. Before spraying, contractors should review the coating manufacturer’s technical data sheet for recommended tip sizes, pressure ranges, thinning requirements and other application instructions.
Where Is Airless Paint Spraying Used?
Airless spray painting is used across residential, commercial and industrial painting and coating applications. Its combination of production capability and equipment configurations makes it suitable for projects ranging from general architectural painting to specialized professional coating work.
Common applications include walls and ceilings, exterior siding, commercial buildings, warehouses, fences, decks, structural surfaces and other areas where efficient coating application is required. Specialized airless equipment and spray tips may also be used for fine finishing, high-production coating applications and line striping.
Airless Spraying vs. Conventional Air Spray
The primary difference between airless spraying and conventional air spraying is how the coating is atomized.
| Airless Spraying | Conventional Air Spray |
|---|---|
| Uses high fluid pressure | Uses compressed air |
| Does not require compressed air for atomization | Requires an air supply for atomization |
| Coating is forced through an airless spray tip | Air interacts with the coating at the spray gun |
| Well suited to high-production applications | Often selected when application requirements favor air atomization |
| Can handle a broad range of coating viscosities | Performance depends on the specific spray system and material |
Neither process is appropriate for every application. The coating being applied, desired finish, production requirements, surface and job-site conditions should all be considered when selecting spraying equipment.
Does Airless Paint Spraying Create Overspray?
Yes. Airless spray painting can produce overspray, particularly when the operating pressure is higher than necessary, the spray tip is not appropriate for the material or spraying technique is poor. For that reason, surfaces that should not receive coating need to be properly protected before spraying begins.
An airless sprayer should not automatically be operated at its highest available pressure. The goal is to use enough pressure to achieve proper atomization and an acceptable spray pattern for the coating being applied. Correct tip selection, appropriate pressure, proper gun distance and consistent spraying technique can help produce a controlled, uniform application.
What Are the Limitations of Airless Paint Spraying?
Although airless spray painting can provide significant production advantages, it requires proper equipment selection, preparation and technique. Overspray and masking requirements must be considered, and the sprayer, hose, gun and related components need to be properly cleaned and maintained. Spray tips also wear over time and may need replacement as their performance changes.
Safety is particularly important because airless equipment operates at very high fluid pressure. Operators should follow the equipment manufacturer’s safety and operating instructions, use appropriate personal protective equipment and never place a hand or other body part near the spray tip or attempt to stop a high-pressure leak with the hand. A high-pressure injection injury requires immediate medical attention. The Occupational Safety and Health Administration (OSHA) also provides guidance and standards addressing spray operations, including potential physical and health hazards associated with spray painting.
How Do You Get a Better Airless Spray Pattern?
A quality airless spray pattern depends on the relationship between the coating, spray tip, operating pressure, equipment and spraying technique. The tip should be properly sized for both the material and the sprayer, while pressure should be sufficient to achieve proper atomization without simply increasing it beyond what the application requires.
The operator’s technique also affects the finished application. Maintaining an appropriate gun distance and angle while moving consistently across the surface helps create a more uniform spray pattern. Heavy edges or “tails” in the pattern can indicate issues such as insufficient pressure, an inappropriate or worn spray tip, coating viscosity or a restriction within the system.
Why Does Airless Spray Tip Size Matter?
Airless spray tip size affects both material flow and spray-pattern width, making it one of the most important variables in an airless system. The selected tip must work with the coating being applied and remain within the output capabilities of the sprayer.
A tip that is too large can demand more material than the pump can consistently deliver, while an inappropriately small tip may restrict material flow or fail to provide the desired application. Tips also wear with use. As the effective orifice becomes larger, material flow and the spray pattern can change, potentially increasing coating use and affecting application consistency.
Matching the spray tip to the coating, sprayer capacity and project helps support efficient airless paint spraying and more consistent equipment performance.
Professional Airless Paint Spraying Equipment From TriTech Industries
TriTech Industries designs and manufactures professional airless spray painting equipment for painting and coating contractors. Its equipment line includes professional airless sprayers, spray guns, T93R spray tips, high-pressure fittings, extensions and other accessories for professional coating applications.
TriTech airless sprayers use Precision Motor Control (PMC), which matches motor output to the pressure and tip size being used. TriTech professional airless sprayers are designed and manufactured in Union, New Jersey, using high-grade stainless steel and aircraft-grade aluminum components.
Explore TriTech professional airless paint sprayers.
Frequently Asked Questions About Airless Spray Painting
What is airless spray painting?
Airless spray painting uses high fluid pressure to force paint or coating through a small spray tip, atomizing the material into fine droplets without compressed air. It is commonly used for efficient coating application across residential, commercial and industrial projects.
Does an airless paint sprayer use compressed air?
No. An airless paint sprayer does not use compressed air to atomize the coating. The pump pressurizes the coating, which atomizes as it passes through the spray tip.
Is airless spray painting faster than rolling?
Airless spray painting is commonly used for high-production applications because it can apply coating across large surfaces much faster than manual brush or roller methods. Actual productivity depends on the project, coating, equipment, preparation and operator technique.
Can you spray thick paint with an airless sprayer?
Many airless spray painting professionals can apply relatively high-viscosity and high-build coatings. The sprayer must have sufficient output and support the tip size required for the material. Contractors should follow the coating manufacturer’s application specifications.
What determines the spray pattern on an airless sprayer?
Spray-tip design and size are major factors in determining fan width and material flow. Operating pressure, coating viscosity, tip condition and spraying technique also affect atomization and the resulting spray pattern.
What pressure should airless paint spraying use?
There is no single pressure setting that is correct for every coating or application. Pressure should be sufficient to achieve proper atomization and a consistent spray pattern while remaining within the recommendations of the equipment and coating manufacturers. Using more pressure than necessary can increase overspray and equipment wear.
What is the difference between airless spray painting and HVLP?
Airless spraying uses pressurized coating passing through a small spray tip to achieve atomization without compressed air. HVLP uses a high volume of air at low pressure to atomize and apply the coating. The appropriate system depends on the material, surface, required finish and production requirements.
Learn More About Professional Airless Spray Equipment
Understanding what airless spray painting is about begins with one basic principle: the coating is atomized using fluid pressure rather than compressed air. From there, equipment capacity, pressure control, spray-tip selection, coating characteristics and operator technique determine how effectively the system performs.
TriTech Industries develops and manufactures professional airless paint sprayers, airless spray guns, spray tips and accessories for painting and coating contractors. Explore TriTech airless spray equipment to compare professional sprayers and equipment designed for different coating and production requirements.
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