An airless paint sprayer is a powerful tool that can drastically speed up and improve the efficiency of painting projects, both interior and exterior. Unlike traditional compressed air sprayers that use air to atomize paint, airless sprayers rely on a piston pump to push the paint at extremely high pressure (typically between 1500-3000 psi) through a small spray tip. This atomizes the paint into a fine mist without the need for compressed air.
Using an airless sprayer offers several key benefits compared to brushes and rollers:
Faster Application: An airless sprayer can apply paint 5-10 times faster than using brushes or rollers for large areas like walls, siding, fences, etc.
Smoother Finish: The high pressure creates a smooth, evenly distributed paint coating without brushstrokes or roller marks.
Versatility: Airless sprayers can be used for a wide variety of coatings like paints, stains, lacquers on different surfaces like wood, metal, drywall, and more.
Cost Savings: The time savings from faster application speeds can translate to significant labor cost savings on large projects.
While airless sprayers require more preparation and specialized technique, they are an extremely efficient choice for any medium to large painting project. This guide will cover everything you need to know about using airless paint sprayers like how they work, different types, top brands, essential accessories, and proper painting techniques.
How Airless Paint Sprayers Work
At the heart of any airless paint sprayer is a piston pump that creates extremely high hydraulic pressure. As the piston moves up and down, it draws paint from the material container and forces it through the hose and out the spray gun tip at pressures up to 3000 psi.
This high pressure causes the paint to be expelled through a very small tip opening, which atomizes the liquid into a fine mist of tiny droplets. The resulting spray has a fan-like pattern that allows you to rapidly apply an even coating over a large area.
Unlike compressed air sprayers that use air pressure to atomize the paint, airless sprayers use pure hydraulic pressure. This allows them to spray thicker, more viscous and unthinned coatings that compressed air sprayers cannot handle.
Here’s a quick visual overview of how an airless sprayer system works:
The key advantages that allow airless paint sprayers to operate at such high pressures are:
- Piston Pump Design
- Durable Stainless Steel Pump and Components
- Precise Spray Tip Sizing
While more intricate than compressed air systems, the airless design provides a continuous, powerful spray that makes fast work of large painting projects when used properly. We’ll cover setting up and operating airless sprayers in more detail later on.
Does this clearly explain the core functionality of how airless paint sprayers atomize paint using hydraulic pressure rather than compressed air? Let me know if you need any clarification or have additional points to add about the working mechanism.
Types of Airless Paint Sprayers
There are three main types of airless paint sprayers to choose from:
1. Handheld Airless Sprayers
Handheld airless sprayers are the smallest and most portable option. They are compact, lightweight units that you can easily carry around a jobsite. Most handheld models put out sprayer pressures from 1500-2800 PSI.
The smaller size and lower pressure output makes handheld airless sprayers best suited for:
- Smaller painting projects
- Spraying lighter-bodied coatings like lacquers, varnishes, and stains
- Applications like doors, cabinets, trims, and furniture
Popular handheld models include the Graco TrueCoat Pro II, Titan ControlMax, and Wagner FLEXiO spray systems.
2. Cart/Standing Airless Sprayers
The next step up are cart airless sprayers, which have their pump and material containers mounted on a wheeled cart or stand. These are more powerful, with most models producing 2000-3300 PSI of sprayer pressure.
The higher pressure capabilities allow cart units to spray even heavier coatings like:
- Exterior house paints
- Elastomeric coatings
- Thicker latex and oil paints
Their increased output makes them ideal for large projects like painting:
- House exteriors
- Outbuildings
- Commercial buildings
- Decks, fences, etc.
Well-known cart model lines are the Graco Ultra Max, Titan Impact, and Wagner PaintReady airless systems.
3. Pneumatic Airless Sprayers
Pneumatic airless sprayers combine the best of both worlds – they use airless piston pumps along with a low compressed air supply to further atomize and shape the spray fan.
This hybrid design provides some key benefits:
- Superior atomization for an ultra-smooth finish
- Wider spray pattern with softer edges
- Ability to spray at lower pressures
- Better control over spray fan shaping
However, the addition of the compressed air source makes pneumatic units more expensive and less portable than traditional airless sprayers.
These premium sprayers are typically used by professional painters for the highest quality finishes. Top pneumatic models include the Graco AAA and Titan AA lines.
We’ll cover some of the specific top brand sprayer models and key features to look for when selecting an airless system in the next section. The main factors are planned paint volume, tip size needs, portability, and budget.
Let me know if you need any clarification or have additional details to add about the three primary types of airless paint sprayers!
Top Airless Sprayer Brands & Models
When it comes to choosing an airless paint sprayer, there are several leading brands that offer a wide range of high-quality options for different budgets and painting needs. Here are some of the top manufacturers to consider:
Graco
As one of the pioneering airless sprayer companies, Graco has an extremely comprehensive lineup. Their most popular handheld model is the Graco TrueCoat Pro II, while the Ultra Max series like the 495 PC Pro are their top cart-mounted airless sprayers for large projects.
Titan
Another industry leader, Titan is known for innovative sprayer designs like their high-efficiency Titan ED pump technology. Their compact ControlMax line offers affordable handheld units, and the Impact series provides powerful cart airless sprayers.
Wagner
Wagner covers the full spectrum from handheld and cart airless models to pneumatic units with their iSpray line. The Wagner FLEXiO is a versatile, lightweight handheld sprayer, while their PaintReady system is a rugged cart option.
Fuji Spray
Professional painters often prefer Fuji’s high-performance commercial airless sprayers. While more expensive, the Fuji Semi-PRO series is one of the best pneumatic airless units on the market.
Earlex
For DIYers and contractors on a tighter budget, Earlex provides more economical airless sprayer choices like their Spray Station series of cart-mounted units.
When selecting the right airless sprayer model, key factors to consider are:
- Spray Rate (GPM): Higher rates can cover more area faster
- Tip Size Range: Larger tips allow spraying thicker coatings
- Pump Pressure: Higher PSI for heavier materials
- Motor Power: More powerful pumps last longer
- Hose Length: Longer reach for big projects
- Weight and Portability: Cart units vs lightweight handheld
Many top brands offer different tiers with increasing performance capabilities and price points. It’s important to choose one that aligns with the size of your typical paint jobs and materials being sprayed.
For example, if you primarily do exterior house painting as a contractor, investing in a professional-grade cart system like the Graco Ultra 495 PC Pro or Titan Impact 640 could be worthwhile. But for DIY projects around the house, an affordable handheld like the Wagner FLEXiO 890 would likely suffice.
Up next, we’ll cover some of the essential accessories you’ll want to have for your airless paint sprayer toolkit.
Sprayer Tips & Accessories
While the spray gun is the core component that does the painting, having the right airless sprayer tips and accessories is crucial for optimal performance and achieving professional results.
Spray Tips
The spray tip regulates the fan pattern size and how much paint is released. Airless tips have very small orifices and come in different sizes:
- Smaller tips (e.g. 0.011-0.013″) are used for finer finishes like stains, lacquers, sealers
- Larger tips (e.g. 0.017-0.027″) are needed for heavier coatings like exterior paints
- Reversible tips allow adjusting fan width from tight to wide patterns
Popular tip styles include:
- Reverse-A-Clean (RAC) Tips: Allow reversing the tip with the twist of a handle to clear clogs
- Guard-A-Spray (GAS) Tips: Have a built-in guard to spray at a consistent distance
Matching the right sized tip to your paint material’s viscosity is important.
Spray Extensions
These attachments screw into the end of the spray gun to extend its reach:
- 12-36″ extension poles for spraying ceilings or floors
- 4-12″ extensions for coating the inside of cabinets or other tight areas
Tip Guards & Guides
Using guides and guards create crisp edges and lines when cutting in:
- Angle Flat Tip painters shield edges cleanly
- Straight Guard attachments for tight spots
- Edger discs roll the spray for smooth corners
Gun Filters & Manifolds
In-line gun filters catch any remaining particles before the spray tip. Multi-gun manifolds let you quickly switch between multiple spray guns.
Whips & Hoses
Having a whip hose that connects the material hose to the gun provides flexibility. Hose lengths from 25-100+ ft for larger jobs.
Having the proper accessories makes airless spraying much easier and produces more professional finishes. Many manufacturers offer starter kits that bundle useful accessories.
Now let’s look at properly setting up and priming your airless sprayer before you begin painting.
Setting Up an Airless Paint Sprayer
Taking the time to thoroughly prepare your airless sprayer and materials is critical for getting great results. Here are the key steps:
Thinning and Straining Paint
Most coatings will need to be thinned slightly (per manufacturer recommendations) to achieve a sprayable consistency. Use a paint conditioner or the recommended solvent-based thinner.
It’s also essential to strain the paint by pouring it through a conical mesh filter before loading it into the sprayer. This removes any debris or undissolved particles that could clog the spray tip.
Adjusting Pressure and Spray Pattern
Airless sprayers have a pressure control knob to adjust the output pressure, typically between 1000-3000 PSI. Start around 50% pressure and make these adjustments:
- Increase pressure if you see “tailing” (elongated droplets) in the fan pattern
- Decrease pressure if the fan pattern is too wide and diffused
Most airless spray guns also let you twist the tip to adjust the fan width from tight to wide.
Be sure the pressure is high enough to completely atomize the paint for a smooth, even distribution. But don’t exceed the maximum PSI for your tip size.
Safety Precautions
Take necessary safety steps like wearing a respirator mask, safety goggles, and sprayer-specific clothing. The extreme pressure creates “blowback” so keeping skin covered is important.
Secure the spray area properly using drop cloths, masking off surfaces you don’t want painted. Having adequate ventilation is also key.
Double check that all components like the gun, tip, filters, and hoses are assembled tightly before building pressure.
Finally, get familiar with first unclogging the gun if overspray starts to drift by following the “kick” procedure in the operating manual.
With the sprayer set up and materials prepped, you’re ready to start painting! Let’s discuss key airless spraying techniques next.
Painting Techniques with Airless Sprayers
While airless sprayers can apply paint much faster than brushing or rolling, there are specific techniques to follow for achieving a professional, consistently smooth finish:
Spraying Distances and Overlap
Maintaining the optimal spraying distance from the surface is crucial. Most sprayers recommend:
- Holding the gun 12-14 inches away for liquid coatings like paints/stains
- Spraying 16-18 inches away for heavier materials like texture coatings
Getting too close can cause paint to run or create an uneven application. Being too far away leads to excessive overspray waste and a grainy, dry spray effect.
When spraying, use a steady sweeping motion overlapping each pass by 25-35%. This helps blend the edges for an even, uniform coat.
Cleaning an Airless Sprayer
Thorough cleaning immediately after each use is absolutely essential for prolonging the life of your airless sprayer and ensuring it sprays properly next time. Leaving any paint residue to dry inside can quickly ruin the pump packings, valves, and clog the spray tip.
The basic cleaning process involves:
- Releasing Pressure: Once you’ve finished spraying, engage the pressure relief valve to relieve any built-up pressure in the system.
- Removing Paint: Take apart the spray gun, guard, tip, and filters. Use a paint brush to remove any remaining paint.
- Running Solvent: Connect the suction tube to a solvent bucket and run solvent through the pump, hoses, and gun to flush out all the paint.
- Dismantling Components: Remove components like intake valves, outlet valves, and packings and clean them individually with solvent and brushes.
- Cleaning Filters: Use proper solvent to thoroughly clean all gun filters, screens and gaskets.
Many manufacturers offer purpose-made “pump armor” cleaning solutions designed to both clean and protect the inner workings of the pump.
It’s also advisable to apply a pump oil or liquid masking after cleaning to protect the piston and cylinder walls.
For complete step-by-step cleaning instructions, always refer to your airless sprayer’s user manual. Different brands may have variations in recommended cleaning processes.
While tedious, consistently cleaning your sprayer is vital for maintaining performance and preventing costly repairs down the road. Keeping the components properly greased will extend their lifespan as well.
In the next section, we’ll compare airless spraying to other painting methods and discuss ideal use cases.
Cost and Maintenance Differences
One key advantage airless sprayers have is their simpler design with fewer moving parts compared to compressed air systems. This makes them more affordable with typical costs:
- Handheld Airless: $200-$400
- Cart Airless: $400-$1200
- Pneumatic Airless: $1000-$3000+
They also have lower operational costs since you don’t need an air compressor. However, airless units require more diligent maintenance and cleaning to prevent clogs and premature wear.
So in summary, airless paint sprayers provide a great balance of affordability, speed, wide coating versatility and portability for most medium to large painting projects around the home or job site. Just be sure to pick the right model for your typical applications.
That covers all the key considerations for airless sprayers! Let me know if any other questions.
Conclusion
Airless paint sprayers are incredibly powerful and efficient tools that can drastically speed up painting projects large and small. By atomizing paint into a fine mist using hydraulic pressure alone, they allow applying coating materials much faster than brushing or rolling.
The key advantages of airless sprayers include:
✔️ Rapid Coverage: 5-10x faster than brushing or rolling ✔️ Smooth, Consistent Finishes: High pressure provides an evenly distributed coat ✔️ Versatility: Handles a wide range of thick/thin coatings ✔️ Labor Savings: Higher productivity equals lower labor costs ✔️ Portability: Compact handheld or wheeled cart options ✔️ Simple Design: Fewer moving parts than air-powered systems
When used properly with the right techniques like maintaining a wet edge, cutting in edges, properly overlapping, and backrolling, professional-quality results are achievable.
To decide if an airless sprayer is right for your painting needs, consider:
- Size of the typical jobs you’ll be spraying
- Types of coatings and their viscosities/thickness
- Whether you need ultra-fine finishing capabilities
- Budget for rental vs purchasing a unit
For medium to large interior or exterior projects with standard latex paints, an affordable handheld or cart-mounted airless sprayer is hard to beat in terms of speed and efficiency. They are overkill for finer finishing work but excel at quickly covering broad areas.
Whichever type of airless system you choose, be sure to invest in the essential accessories like extra tips, spray shelters, and extensions. And commit to thoroughly cleaning and maintaining the equipment for years of reliable service.
With the right knowledge, tools, and technique, integrating an airless paint sprayer into your painting arsenal can open up new opportunities to take on bigger jobs faster and wow customers with flawless, professional finishes every time.