Airless Sprayer Tip Size Calculator
Determine the correct airless sprayer tip size based on your desired spray fan width and flow rate (GPM). Tip codes are read as: first digit × 2 = fan width (inches), last two digits = orifice size (thousandths of an inch).
Formulas Used
Tip Code: First digit = Fan Width (in) ÷ 2 | Last two digits = Orifice size in thousandths of an inch
Orifice Size (thou):
orifice = √( GPM × ViscosityFactor / (0.0009 × √PSI) ) × 1000
Actual Flow Rate:
GPM = 0.0009 × orifice² × √PSI / ViscosityFactor
Spray Rate:
sq ft/min = GPM × (400 / ViscosityFactor)
Tip Life:
Gallons = orifice_thou × 40
Assumptions & References
- Tip code convention: first digit × 2 = fan width in inches; last two digits = orifice in thousandths of an inch (e.g., tip 515 = 10" fan, .015" orifice).
- Flow rate formula derived from the Graco/Titan industry standard: GPM ≈ 0.0009 × orifice² × √PSI.
- Viscosity factors: Water/stains = 1.0, Standard latex = 1.15, Heavy latex = 1.30, Texture = 1.50.
- Coverage estimate based on ~400 sq ft/gal at 4 mil wet film thickness for standard latex; adjusted by viscosity factor.
- Tip life estimate: ~40 gallons per thousandth of orifice diameter (industry rule of thumb for carbide tips).
- Standard orifice sizes rounded to nearest odd thousandth (9–45 thou) per manufacturer availability.
- Recommended operating pressure range: 1500–3000 PSI for most coatings; consult material TDS for exact requirements.
- References: Graco Tip Selection Guide; Titan Tool Tip Charts; Wagner SprayTech Application Guides.