Powder Coating Calculator

The calculator converts your powder density into specific gravity (density ÷ 8.33) and divides the reference coverage of 192.3 sq ft/lb by that specific gravity. A denser powder packs more mass into the same volume, so a given weight of it spreads over a thinner film — meaning a lighter powder (lower specific gravity) actually covers more area per pound at the same target thickness, and the calculator's coverage rate falls as density rises.

Transfer efficiency represents the fraction of sprayed powder that actually sticks to the part on the first pass; the calculator divides the theoretical powder-per-part figure by that percentage, so a lower efficiency inflates the real consumption. At 65% efficiency you need roughly 1.5x the theoretical powder weight per part, since more than a third of what you spray ends up as overspray rather than coating.

It's 95% of whatever powder didn't transfer to the part — the portion a cyclone or cartridge reclaim booth is assumed to capture and reuse. It's a planning estimate for a well-maintained reclaim system, not guaranteed savings; a booth without reclaim, or one running mixed colors where reclaimed powder can't be reused, will recover much less than this figure suggests.

No — it's a rough heuristic of 10 minutes plus part surface area divided by 500, meant only to reflect that larger, higher-mass parts take longer to reach cure temperature throughout. Your powder manufacturer's technical data sheet specifies the real cure schedule (commonly 10-20 minutes at 400°F), and that schedule — not this estimate — should govern your actual oven settings.