We often see debates online and talk to customers old and new, to recommend the best spray tips and filters. Getting the wrong Tip size can result in poor and messy application and having the wrong or no filters can damage your spray machine and cost a lot of money to repair. so we thought we would put together a Chad’s Tips that could be used as a great starting point.
A TDS (Technical data sheet) will specify what tip size is recommended to spray their product.
So one data sheet for intumescent material may state that you need a tip size of 21” and a spraying pressure of 2000 PSI and a data sheet for a thinner paint like lacquer may specify a tip size of a 13” and a spraying pressure off 2000 PSI
It is dependent on the viscosity of the material you are spraying but there are other factors that come into play, which is why if you’re note sure, we’re here to help.
Choosing the correct tip size for a paint or plaster spray project is crucial for getting good coverage, avoiding clogs, and ensuring a professional finish. Here’s what you should take into account:
1. Material Viscosity
Different materials require different tip sizes:
- Thin materials (e.g., stains, lacquers): Smaller tips (e.g., 0.009–0.013 inches)
- Medium materials (e.g., latex paints): Medium tips (e.g., 0.015–0.019 inches)
- Thick materials (e.g., primers, heavy latex, plaster): Larger tips (e.g., 0.021–0.035+ inches)
2. Sprayer Type
Not all sprayers can handle large tips:
- Airless sprayers: Better for high-viscosity materials and can support larger tips
- HVLP (High Volume Low Pressure): Best for thinner materials and fine finishes; usually uses smaller tips
3. Tip Fan Width
Each spray tip has two numbers (like 517):
- First digit (5) = fan width × 2 → 10” spray pattern at 12” from the surface
- Second two digits (17) = orifice size in thousandths of an inch (0.017”)
- Wider fan width = better for broad areas
- Narrow fan width = more control, better for detailed or trim work
4. Surface Type and Size
- Large walls/ceilings: Wider fan pattern, larger tip
- Trim, cabinets, furniture: Narrower fan, smaller tip
- Textured surfaces: May require a larger tip and higher pressure
5. Sprayer Capacity & Manufacturer Specs
Always check:
- The maximum tip size your sprayer can handle
- The recommended tip sizes for specific materials from the paint manufacturer
6. Project Duration and Frequency
- Larger tips = faster coverage but more overspray
- For DIYers or one-time use, smaller tips can be easier to manage
- For pros doing repetitive work, tip longevity and speed matter
Choosing the correct spray tip is only one aspect of ensuring perfect paint application. Having a filter which compliments your chosen tip, allowing the material you are spraying to flow easily, whilst still protecting the integrity of your spray machine and gun is just as important.
The image above demonstrates that the lower the filter number the wider or the more course the filter. Meaning the higher the number the more filtration.
In layman’s terms, the 200 mesh is like trying to put paint through a pair of tights. And the 30 mesh is like putting paint through a kitchen sieve. The holes in the mesh filter are bigger the lower the mesh size you choose.
For thicker material where you are using a tip size of a 19” onwards, you’d use a 30 mesh. Using a too fine a filter, like the 60 mesh could result in the wrongly used filter either getting crushed or split. The paint can’t pass through it, and under pressure it will find the easiest way through the filter, the path of least resistance, allowing the material to get through and be UNFILTERED.
Here are a couple of instances where machines have broken because they have been used, without strainers.
This is a rod in a Graco Mark V. The spray machine came in for repair because it has stopped working as a result of not having a strainer. A strainer would help filter out stones, plastic tags, wires and all sorts of debris that you find on a site.
- This is the cylinder of a different Mark V spray machine. This is what a rod moves up and down through. Something has been sucked up and got between the packings on the rod and the cylinder and has caused some serious damage.
Getting the correct tips and filters for the material you are spraying and the machine you are using is essential in ensuring and efficient and profitable job, that delivers a professional, high quality finish. If you would like more advice, get in touch with our expert team, via the phone, e-mail or chatbot.