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Airless vs. airless air-assisted sprayers: what’s the difference?
When it comes to professional painting and coating applications, choosing the right spray equipment is crucial. Two of the most common technologies used in industrial and commercial settings are airless sprayers and airless air-assisted sprayers. But what exactly is the difference between them?
In this guide, we’ll break down the key distinctions, benefits, and ideal applications for each system.
What is an airless sprayer?
An airless sprayer is a high-pressure spraying system that atomises paint or coating materials without the use of compressed air. Instead, it relies on hydraulic pressure, forcing the material through a small nozzle at high speed. This creates a fine spray pattern that provides excellent coverage and penetration.
Benefits of airless sprayers:
- High efficiency: Airless sprayers can cover large surfaces quickly, reducing labour time and making it ideal for large projects
- Superior finish: Ideal for thicker coatings such as primers, latex paints, and industrial coatings. Due to the high-pressure application, coatings adhere better to the substrate, making them ideal for rough or uneven surfaces
- Versatility: Using different tips with your machine allows you to spray a wide range of materials
- Portability: Airless units are also more portable, as they don’t require a compressor
Ideal applications:
- Large-scale commercial and industrial painting
- Protective coatings for steel structures
- Exterior house painting
- Marine and automotive refinishing
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What is an airless air-assisted sprayer?
An airless air-assisted sprayer combines the principles of airless spraying with a small amount of compressed air to refine the spray pattern. While the fluid is still pressurised and delivered through an airless system, a secondary air supply helps improve atomisation and control.
Benefits of airless air-assisted sprayers:
- Lower operating pressure: Less fluid pressure is required to break up the same material, making the process more efficient than with airless sprayers. It also reduces wear on equipment components, leading to longer service life
- Better quality finish: You can achieve a slightly finer finish compared to airless sprayers. By introducing assist air into the fluid stream, you get a finer breakup and finish, making it ideal for fine-finish jobs
- Reduced material waste: These sprayers tend to waste less material than airless sprayers, improving efficiency and reducing costs
Ideal applications:
- Wood finishing (e.g., furniture)
- Automotive refinishing
- Metal fabrication and industrial coatings requiring a finer finish
- Aerospace and high-precision painting applications
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Which one should you choose?
The choice between an airless sprayer and an airless air-assisted sprayer depends on your specific application needs:
- If you need to cover large surfaces quickly with high-viscosity coatings, an airless sprayer is the best choice
- If you require a fine, controlled finish with reduced overspray, an airless air-assisted sprayer is the better option
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Conclusion
Both airless and airless air-assisted sprayers have their advantages, and the right choice depends on your project’s demands. Whether you’re working on large-scale industrial applications or precision finishing, selecting the appropriate sprayer will ensure the best results in terms of efficiency, finish quality, and cost-effectiveness.
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