Manual spray guns are a versatile and powerful tool that can be used to apply a wide variety of coatings to a multitude of surfaces. They are used in a lot of industries, including automotive, aerospace, manufacturing, and woodworking.
This guide will teach you all the basics about manual spray guns. The purpose of this comprehensive is to guide you with the key information you need to select the ideal manual spray guns for your coating projects.
What are manual spray guns?
A manual spray gun is a tool used to apply a coating to a surface by atomizing a liquid and propelling it through the air. Manual spray guns are typically powered by compressed air, but some models, for specific applications, can also be powered by electricity or batteries.
Manual spray guns are available in a variety of sizes and types, depending on the application. Some unique and key features of manual spray guns include:
Trigger mechanism: The trigger controls the flow of coating material. Pulling the trigger opens a valve to allow material to flow through the nozzle. Releasing the trigger stops the flow.
Air hose: Air hoses connect the manual spray gun to an air compressor or pressurized air source which provides the air to atomize the paint.
Adjustments: Controls on the manual spray gun allow the user to adjust and fine-tune the air pressure, fluid flow rate, and spray pattern shape. In digital models, the settings can be presented and adjusted using a small screen.
Advantages and disadvantages of manual spray guns
Manual spray guns are a popular tool for applying coatings to a variety of surfaces. They offer a number of advantages over other methods, but they also have some disadvantages. Let’s see first some advantages, and later the disadvantages of using manual spray guns.
Advantages of manual spray guns
Versatility: They can be used to apply a wide variety of coatings, including paints, stains, and lacquers. They can also be used to apply coatings to a lot of different surfaces, including metal, wood, and plastic.
Speed: Manual spray guns can apply coatings much faster than other methods, such as brushing or rolling. This can be a significant advantage for large projects or industrial applications where high throughput is required.
Smooth finish: They can apply coatings more evenly than other methods. This is important for achieving a high-quality finish, like that required for automotive refinishing.
Cost-effectiveness: Manual spray guns are relatively inexpensive, especially when compared to other methods of applying coatings. This makes them accessible even to hobbyists and small operations.
Control: The user has direct control over where the spray is directed. Operators can control the spray pattern, flow rate, and other factors on the fly. This allows for precise application.
Portability: They are lightweight and easily moved compared to automated or fixed spray equipment. This allows for use in many locations, and touch-ups on site, when needed. Minor coating repairs are easily completed with a manual spray gun instead of taking up production time on automated lines.
Simplicity: Basic manual spray guns are fairly simple devices with few moving parts. This makes maintenance and repair straightforward.
Disadvantages of manual spray guns
Overspray: Manual spray guns can produce a significant amount of overspray, which is wasted material and can also pose an environmental hazard. Controlling the spray pattern and drift might be difficult. The operator plays a crucial role in the amount of overspray that can occur. It is important to take steps to reduce overspray, such as using a spray booth or wearing a respirator.
Safety: Manual spray guns can be dangerous if not used properly. It is important to wear safety gear, such as eye protection, a respirator, and gloves, when using a spray gun.
Learning curve: They can be difficult to learn how to use properly. It is important to practice before using a spray gun on an important project. Maintaining a consistent spray pattern and coating thickness is user-dependent and difficult to sustain. Proper spray gun handling and application technique requires training and practice to master.
Labor-intensive: The user has to hold and manipulate the spray gun, which can be tiring over time. It requires skill and proper technique.
Speed: The application is slower compared to automated spray systems.
Cleanup: Cleaning a manual spray gun thoroughly after use involves more labor and solvent use.
Why are manual spray guns needed for industrial finishing?
Mastering manual spray gun technique allows you to achieve professional-looking finishes on everything from furniture to automotive bodies. With the proper spray gun skills, you’ll reduce paint waste, improve consistency, and bring out the high-quality finishes your work deserves.
In addition to these general advantages, there are other reasons why to use manual spray guns for industrial finishing, such as:
Ability to handle high-volume applications: They can be used to apply coatings to large surfaces and complex shapes. This is important for industrial applications where large volumes of products need to be finished quickly and efficiently.
Ability to apply a wide range of coating materials: Manual spray guns can be used to apply a wide range of coating materials, including paints, stains, lacquers, and powder coatings. This makes them ideal for a lot of industrial applications.
Durability: They are designed to withstand the rigors of industrial use. They are typically made from durable materials and are built to last.
Precision: The manual control allows workers to direct the spray precisely into hard-to-reach areas or to coat complex shapes and profiles. This level of precision is difficult to achieve with automated equipment.
Small production runs: Manual spray guns allow small items or custom jobs to be coated cost-effectively without setting up a large, automated line. This is especially important when producing prototypes or limited series of a product.
While automation has its place, manual spray gun skills remain a vital competency for many industrial finishing jobs. The flexibility and control they provide complements high-volume automated finishing.
Not all manual spray guns are the same
Manual spray guns are available in a variety of sizes and types, depending on the application. Some of the most common types of manual spray guns include:
Conventional: This is the most common type of manual spray gun. They use a combination of compressed air and fluid to atomize the coating and propel it through the air. They don’t include many technological components but are rather basic devices.
HVLP: HVLP (high volume, low pressure) spray guns use a lower air pressure than conventional spray guns, which results in less overspray. HVLP manual spray guns are often used for applications where a high-quality finish is required, such as automotive painting.
LVLP: LVLP (low volume, low pressure) spray guns use even lower air pressure than HVLP spray guns, which results in even less overspray. LVLP spray guns are often used for applications where a very high-quality finish is required, such as marine painting.
Airless: Airless spray guns do not use compressed air to feed the paint to the fluid tip. Instead, the paint is forced through the fluid tip by a pump. Airless spray guns are often used for heavy-duty painting applications, such as painting bridges and buildings. A variety of this type are Air Assisted spray guns.
Electrostatic: Electrostatic spray guns can use either liquid or powder coating to spray over a surface using an electric discharge. They are widely used to increase savings and reduce application time.
Another way to categorize manual spray guns
Besides the technology a manual spray gun might have, another way to categorize them is through the way they are fed, which can be:
Gravity: They rely on gravity to feed the paint to the fluid tip. The paint cup is located on top of the spray gun, and the paint flows down to the fluid tip by gravity. The cups can be metallic, plastic or even disposable. They can hold anything from 1 liter to 100 cc of paint, depending on the use of the spray gun. These models are widely used for automotive refinishing.
Pressure: These use pressurized air to feed the paint to the fluid tip. The paint cup is located under the spray gun, and the paint is forced up to the fluid tip by pressurized air. Usually, tanks are used to store the coatings and paint pump distribute it thought the production lines. These models are commonly used in industrial finishing lines.
Suction: A less common type of manual spray guns are the ones fed by suction. They use compressed air to create a vacuum which effectively siphons paint up from the paint container and into the spray gun. This type of spray gun is typically used for spraying low to medium viscosity paints, such as latex paints and primers.
Parts of a manual spray gun
These are the main parts and components of a typical manual spray gun:
Air cap: The air cap is the part of the spray gun that controls the shape and size of the spray pattern. It also contains the air orifice, which is the hole through which the compressed air flows.
Fluid tip: The fluid tip is the part of the spray gun that controls the flow of paint. It also contains the fluid orifice, which is the hole through which the paint flows.
Needle: The needle is the part of the spray gun that opens and closes the fluid orifice. It is controlled by the trigger.
Trigger: The trigger is the part of the spray gun that is used to control the flow of paint. When the trigger is pulled back, the needle opens and paint flows through the fluid orifice. When the trigger is released, the needle closes, and the flow of paint stops. Most spray guns include a guard, which is a metal piece protecting the trigger area from accidental activation.
Handle: The handle is the part of the spray gun that is held by the user. Ideally, it is a shaped grip for holding the gun steady with the trigger finger.
Paint filter: It is a little screen located in the cup and/or fluid inlet to remove dirt and debris from the paint supply. This is important to prevent the spray gun from clogging and to produce a smooth finish.
Air filter: The air filter removes dirt and moisture from the compressed air supply. This is important to prevent the spray gun from clogging.
Air hose: The air hose connects the spray gun to the compressed air source. Usually, it has to be bought separately.
Fluid hose: The fluid hose connects the spray gun to the paint supply. Usually, it has to be bought separately.
Paint Cup: In the case of gravity or suction spray guns, a metal or plastic cup that attaches to the gun and holds the paint is part of the kit. It should have a large filling hole.
Adjustment Knobs: They are used to control the amount of air pressure, pattern width, and fluid flow. It can be digital or analog.
The most important features for manual spray guns
The most important features to consider when selecting a manual spray gun for industrial finishing include:
Atomization quality: This is the ability of the spray gun to break up the coating into fine droplets. A good spray gun will produce a uniform and consistent spray, with minimal overspray.
Transfer efficiency: This is the percentage of coating that is actually transferred to the surface being sprayed. A good spray gun will have a high transfer efficiency, which reduces waste and saves money.
Comfort and ease of use: The manual spray gun should be comfortable, lightweight, and balanced to hold and use for extended periods of time. Rubber grips can help. It should also be easy to adjust and clean.
Reliability and durability: It should be made from high-quality materials and be able to withstand the rigors of everyday use. Components like the nozzle, fluid tip, and needles should withstand constant exposure to solvents and coatings without seizing up.
Maintenance: Quick access to internal parts for cleaning and rebuilding is vital for maintenance. Fewer parts speeds disassembly.
Main applications for manual spray guns
Manual spray guns are commonly used in industrial finishing applications. Here are some specific examples:
Automotive painting: Manual spray guns are used to paint cars, trucks, and other vehicles. They can produce a high-quality finish with minimal overspray, which is important for the automotive industry. The same is true for automotive refinishing.
Furniture finishing: They are widely used to finish wood furniture. They can produce a uniform coating on complex shapes, such as chair legs and tabletops.
Marine painting: They can produce a uniform coating on ships and boats that is resistant to corrosion and other environmental factors.
Aircraft painting: Manual spray guns can be used to produce a uniform coating on complex shapes, which is important for aircraft performance.
Metal finishing: They are needed in the metalworking industry to apply coatings to a variety of metals, such as steel, aluminum, and copper. These coatings can protect the metal from corrosion and other environmental factors, or they can provide a decorative finish.
Plastics finishing: Manual spray guns are used to apply coatings to a variety of plastics, such as ABS, PVC, and polycarbonate. These coatings can protect the plastic from UV radiation, chemicals, and other environmental factors, or they can provide a decorative finish.
Wood finishing: They are ideal to apply coatings to a variety of wood products, such as plywood, MDF, and hardwood. These coatings can protect the wood from moisture, UV radiation, and other environmental factors, or they can provide a decorative finish.
How to choose a manual spray gun
The first thing to consider when choosing a manual spray gun is what application you need it for. Do you need it to paint metallic or plastic objects? Is it for an industrial production line or for touch ups? Is it to paint cars or heavy machinery? Some of them can be used for more than one application, but as a rule of thumb it is better to have dedicated manual spray guns.
When choosing a manual spray gun, it is important to consider the following factors:
Fluid viscosity: The fluid viscosity must be correct for the spray gun to operate properly. If the fluid is too thick, it will not flow easily through the spray gun. If the fluid is too thin, it will produce a light coat of paint.
Fluid pressure: The fluid pressure controls the flow of coating material from the spray gun. A higher fluid pressure will produce a faster flow of coating material, while a lower fluid pressure will produce a slower flow. The correct fluid pressure will depend on the type of coating you are using and the desired finish.
Air pressure: The air pressure controls the atomization of the coating material. A higher air pressure will produce a finer atomization, while a lower air pressure will produce a coarser atomization. The correct air pressure will depend on the type of coating you are using and the desired finish.
Spray gun type: There are a variety of spray gun types available, including conventional, HVLP (high volume, low pressure), and LVLP (low volume, low pressure). Each type has its own advantages and disadvantages, so it is important to choose the right type for your needs.
Air cap size: The air cap size determines the width and shape of the spray pattern. Larger air caps produce wider spray patterns, while smaller air caps produce narrower spray patterns.
Fluid tip size: The fluid tip size determines the flow of paint. Larger fluid tips produce a higher flow of paint, while smaller fluid tips produce a lower flow of paint.
Needle size: The needle size must match the fluid tip size. If the needle is too small, it will restrict the flow of paint. If the needle is too large, it may not be able to close the fluid orifice completely, which can lead to dripping.
Tips for using manual spray guns
Spray guns can be a valuable tool for applying coatings to a variety of surfaces. That does not mean that just by grabbing one you are going to be able to perform an outstanding job. It is important to learn how to use them properly to achieve a high-quality finish and to reduce overspray. Here are some tips for using manual spray guns safely and effectively:
Choose the right spray gun for the job: There are a variety of spray guns available, so it is important to choose the right one for the type of coating you are applying and the desired finish.
Adjust the spray gun settings properly: The spray gun settings will affect the quality of the finish and the amount of overspray. It is important to adjust the settings properly for the coating you are using and the desired results.
Use the correct spray technique: The spray technique is also important for achieving a high-quality finish and reducing overspray. Test the spray gun on a scrap piece of material before using it on your project. Move the spray gun in a steady, sweeping motion. It is important to hold the spray gun at the correct distance from the surface and to move it at a consistent speed. Start spraying from a distance of about 12 inches and move closer to the surface until you achieve the desired finish. Apply multiple thin coats of coating rather than one thick coat.
Care for safety: Wear safety gear, such as eye protection, a respirator, and gloves. Use a spray booth or work in a well-ventilated area to reduce overspray.
Clean the spray gun thoroughly after use: This will help to prevent the spray gun from becoming clogged and ensure that it performs properly the next time you use it.
Why DeVilbiss manual spray guns are so famous
DeVilbiss is a leading brand of industrial finishing equipment that has become well-known for their high-quality, durability, and high-performance manual spray guns. They are used by professionals in a wide range of industries, including automotive, aerospace, industrial, and woodworking. Here are some of the reasons why DeVilbiss manual spray guns are so popular:
High quality: DeVilbiss spray guns are made with high-quality materials and construction. They are built to last and can withstand the rigors of everyday use. Some DeVilbiss spray guns have been in use for 50 years or more.
Durability: They are very durable and can withstand a lot of wear and tear. They use durable materials like stainless steel, anodized aluminum, and brass. These withstand constant contact with solvents and are resistant to corrosion and other damage.
Performance: DeVilbiss spray guns provide excellent atomization and allow for very precise adjustment of the fan pattern and fluid flow. This produces a fine and consistent spray, with minimal overspray. This results in a high-quality finish on the coated surface.
Ergonomics: They are designed to be comfortable and easy to use. They have a lightweight and ergonomic design that reduces fatigue. DeVilbiss has been manufacturing spray guns since the 1920s. Many of their models use time-tested designs refined over decades of use.
Innovation: DeVilbiss is a leader in spray gun technology. They are constantly innovating and developing new products that improve the spray gun experience.
Customizable and easy to maintain: Their spray guns are designed for quick disassembly and cleaning. Replacement parts and rebuild kits are readily available. A wide range of air caps, fluid tips, and nozzles allow the manual spray guns to be customized for specific coating needs.
Manual spray guns: Last thoughts
Whether you’re an experienced spray painter or a DIY enthusiast venturing into your first paint job, a quality manual spray gun is an essential tool for applying coatings smoothly and efficiently.
Getting the right manual spray gun for your application is essential to achieve the desired results. We have decades helping companies to set up industrial finishing production lines. Feel free to reach out to us so we can help you too.
