Thermal Spray Calculator

Calculate thermal spray coating feedstock consumption, deposit efficiency, and costs for HVOF, plasma, wire arc, and flame spray.

Surface area (sq in)

Target thickness (mils)

Spray process (1-4)

Coating density (lb/in³)

Feed rate (lb/hr)

Feedstock cost ($/lb)

Labor rate ($/hr)

Tab to move between fields

Feedstock required (lbs)

0.41

Total cost ($)

$13.90

≈ 3 cups of coffee

Coating weight (lbs)0.29

Overspray waste (lbs)0.12

Deposit efficiency (%)70

Spray time (minutes)1.7

Feedstock cost ($)$10.32

Labor cost ($)$2.34

Gas/consumables ($)$1.24

Cost per sq in ($)$0.14

How to Use This Calculator

How the result changes with Surface area (sq in)

Coating weight (lbs): Weight of coating deposited on part.
Feedstock required (lbs): Total feedstock needed including overspray losses.
Overspray waste (lbs): Feedstock lost to overspray.
Deposit efficiency (%): Percentage of feedstock that lands on the part.
Spray time (minutes): Estimated spraying time.
Feedstock cost ($): Total feedstock material cost.
Labor cost ($): Operator labor cost.
Gas/consumables ($): Estimated gas and consumable costs.
Total cost ($): Total coating cost.
Cost per sq in ($): Unit cost per square inch coated.

Identify Input Parameters
4 parameters
Surface area (sq in) = 100, Target thickness (mils) = 10, Spray process (1-4) = 1, Coating density (lb/in³) = 0.289 = 7 input(s) provided
Calculate Feedstock required
Feedstock required = coatingWeightLbs / de
0.41 = 0.41
Calculate Total cost
Total cost = feedstockCost + laborCost + gasCost
13.9 = $13.9
Calculate Coating weight
Coating weight = coatingVolumeCuIn * coatingDensityLbIn3
0.289 = 0.289
Calculate Overspray waste
Overspray waste = feedstockRequiredLbs - coatingWeightLbs
0.12 = 0.12