Using the wrong painting equipment can lead to frustration at best and disaster at worst. Just like you wouldn’t use a paint brush for a tall building, you also wouldn’t want to use an airless paint sprayer for fine details. But it’s nevertheless a highly efficient tool. Let’s dive into detail about what an airless paint sprayer is and what you should use it for.
How An Airless Sprayer Works
An airless sprayer works by pumping paint at high pressure through a small opening in the spray gun. This creates atomization: the breaking up of paint into a fine mist. An airless paint sprayer is, therefore, different from an air paint sprayer, which uses compressed air to atomize the paint.
The sprayer’s tip size and pressure play a role in how the airless paint sprayer works. First of all, they affect the flow rate: the smaller the tip size and the higher the pressure, the faster the paint will be sprayed. Moreover, the tip size also creates the spray fan pattern, which may be larger or smaller. Some tips are better for applying varnish, while others work for latex paint.
The high pressure of the paint stream allows for faster application and great coverage, making it ideal for large-scale painting projects. However, it has both pros and cons.
The Pros of an Airless Paint Sprayer
An airless paint sprayer creates ultra-smooth coverage of large surfaces quickly. It’s a time-efficient option for large painting projects. Furthermore, it’s a champ at evenly distributing paint, resulting in a professional-looking, uniform outcome.
An airless paint sprayer is also a great option for wood. Instead of spending hours applying paint with a brush or roller, you can cover the same area in a fraction of the time. You can also use it to spray lacquer.
No matter which paint you use, you should get a better, smoother, more professional-looking result than if you use a paint brush or a roller. Its high efficiency makes it stand out among other options. Unlike an HVLP sprayer, an airless paint sprayer is the best at handling high-viscosity, thick paints. For instance, thick latex paints and primers.
Moreover, some airless sprayers don’t require an external power source. These sprayers are portable and convenient to use. But they’re only suitable for low-viscosity paints like lacquer or stain.
Spray painting is always a challenge, but it’s achievable (read our spray painting guide). Although HVLP sprayers are a bit easier to use, you can get the hang of airless sprayers if you follow your instructions.
Pros:
- Fast
- Applies a lot of paint at once
- Practical
- Smooth
- Portable options (for low-viscosity paints)
- Great at handling thicker paints
- Great for woodwork and applying lacquer
- Applies a lot of paint at once; great for large projects
The Cons of an Airless Paint Sprayer
| Pros | Cons |
| Fast | Expensive |
| Applies a lot of paint at once | Lower transfer efficiency than HVLP |
| Practical | Difficult to master |
| Smooth | Bad for painting details |
| Portable options (for low-viscosity paints) | Prep time |
| Great at handling thicker paints | Maintenance |
| Great for woodwork and applying lacquer | Cleanup |
| Applies a lot of paint at once; great for large projects |
But just because an airless paint sprayer is great at what it does doesn’t mean that using it is always a walk in the park. It’s not always as effective as a HVLP sprayer.
Transfer rate refers to how much paint covers the surface versus how much is wasted. The transfer rate of an airless sprayer is only 70 to 80%. On the other hand, an HVLP sprayer’s transfer rate is 80 to 90%. It’s a bit easier to use, too.
Additionally, an airless sprayer is more expensive and more difficult to prep, maintain, and clean up. And we all know that spray painting can get messy (but don’t worry; you can check out our guide to cleaning up paint spills and drips).
Cons:
- Expensive
- Lower transfer efficiency than HVLP
- Difficult to use
- Bad for painting details
- Prep time
- Maintenance
- Clean up
When to Use an Airless Paint Sprayer
When you have a large area to cover, such as the exterior of a house, a fence, or a large commercial space, an airless paint sprayer can significantly speed up the process. Additionally, if you want a smooth and flawless finish, an airless paint sprayer is the way to go.
However, if you’re working on smaller projects or have limited time for prep and maintenance, it may be more practical to use traditional painting methods or an HVLP sprayer. It can also save you money.
Safety While Using an Airless Paint Sprayer
Remember to follow safety procedures while using your airless sprayer. Here are some safety precautions you need to take:
- Use the sprayer in a well-ventilated area.
- Keep the trigger locked and follow the pressure relief procedure whenever you’re not spraying. Make sure you also do this before you service the sprayer or install tips.
- Use a tip guard when spraying.
- Always point your spray gun away from yourself and others.
- Don’t put your hand in front of the sprayer tip unless you’re sure it’s off and depressurized. Its high pressure can cause serious injuries and even poisoning.
- Keep your work area free of debris.
- Read and save the safety instructions that come with your airless sprayer.
- Use safety equipment such as gloves, goggles, a respirator, and suitable clothes. See more about the equipment you need below.
The Cost of Using an Airless Paint Sprayer
An airless paint sprayer is more costly than an HVLP paint sprayer. And on top of that, you still need to invest in safety equipment and paint. However, it may be worth the flawless finish you’re looking for for your large surface.
Here’s the safety equipment you’ll need:
| Safety Equipment | Estimated Cost |
| Disposable gloves | $9 (for 100) |
| Safety goggles | $9 |
| Respirator (for spray painting) | $17 to $60 |
| Total | $35 to $78 |
Here’s the painting equipment you’ll need:
| Painting Equipment | Estimated Cost |
| Paint | $10 to $100 per gallon |
| Airless paint sprayer | $150 to $500 |
| Paint strainer | $8.50 for a pack of 50 |
| Tarp | $12 |
| Painter’s tape | $5 |
| Total | $185.50 to $625.50 |
The total of your project should come to at least $220.50 but may cost more depending on your project size. Remember that you’ll need to account for the amount of paint you need. One gallon of paint covers approximately up to 400 square feet (and you’ll need to apply multiple coats).
FAQ
What is the number one rule when using airless spray guns?
One of the most important things about using an airless spray gun is to keep a distance of 1 foot (12 inches) from the surface. Also, be sure that you hold your sprayer at a perpendicular angle.
How do you get a good spray pattern?
To get a good spray pattern, adjust the spraying pressure with the pressure control knob. Your spray pattern should be smooth with no runs.
Do you get overspray with an airless paint sprayer?
Yes, an airless paint sprayer sprays thick coats quickly. Therefore, overspray can occur. Be sure to mask off surrounding areas to prevent overspray from getting on unwanted surfaces. If you use low pressure, there will be less overspray. On the other hand, high pressure means more overspray.
Why does my airless sprayer keep clogging?
There are a few reasons your airless paint sprayer might clog. For example, your spray pressure might be too high. You could also be using the wrong type of paint—one that hardens quickly. To further prevent clogging, you can strain the coating with the right strainer.
What is paint viscosity?
Paint viscosity refers to the thickness or consistency of the paint. It determines how easily the paint flows and spreads when applied. As a rule of thumb, the best paint viscosity for paint spraying and manual painting is 100 cps.
Final Thoughts
When it comes to large-scale paint jobs, an airless paint sprayer is a game-changer. Not only does it allow for faster coverage, but it also ensures a smooth-looking result. Whether you’re tackling a house, a fence, or a commercial space, the efficiency and quality of an airless paint sprayer can’t be beaten. No matter which job you’re taking on, be sure to check out these common mistakes DIY painters make.
However, a DIY airless paint sprayer project isn’t for everyone. While some homeowners may persist in tackling it, others may find professional painting options more cost-effective and efficient. If that’s you, find a pro in your area.
Main Photo Credit: ozdigital / Canva Pro / License
