Aircoating

Air coating is a coating application method in which a liquid coating is atomized into a fine mist and projected onto a surface using compressed air. The resulting spray forms a continuous film after the solvent evaporates or the coating cures. There are several spray technologies, including conventional air spray, air-assisted airless spray, and electrostatic spray, each delivering different droplet sizes, transfer efficiency, and coverage patterns. The equipment used ranges from handheld spray guns to robotic spray systems and automated booths.

Materials applied by air coating include paints, varnishes, lacquers, sealants, and other protective or decorative coatings. They are formulated for various substrates such as metal, wood, plastic, and composite materials, with viscosities and solids contents tuned to optimize atomization and film formation.

Typical workflow involves surface preparation (cleaning, degreasing, and sometimes sanding), masking of edges, setting spray parameters (nozzle size, air and fluid pressures), applying multiple thin coats to achieve the desired dry film thickness, and controlled curing or drying under specified temperatures and times.

Advantages of air coating include controllable film thickness, compatibility with a wide range of coatings, and good surface finish on complex geometries. Limitations include overspray and waste, environmental and health concerns from solvents and VOCs, drift due to air movement, and equipment costs. Ongoing trends focus on high-solids and waterborne formulations, electrostatic charging to improve transfer efficiency, and automation to enhance consistency and productivity.