Powder Coating Coverage Calculator

Inputs

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Total part surface area receiving powder. Include both sides, formed surfaces and repeat quantity.
ft²
Target cured dry film thickness. Common architectural and industrial powder specs often sit around 2-4 mil.
mil
Powder density relative to water. Use the coating data sheet when available.
First-pass powder that sticks to the part before reclaim. Do not include reclaim in this number.
%
Percent of overspray recovered for reuse. Use 0 for no reclaim or color-change work.
%
Extra allowance for purge, hose/gun setup, booth cleanup, rejects and small-batch handling.
%
Material price per pound of powder. Labor, pretreatment, masking, energy and rework are not included.
$/lb

Results

Default result
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Powder to plan(m_plan)
19.81lb
Pass

net fresh powder plus setup waste allowance

Also computed

Powder material cost(Cost)Pass158.47$

uses 19.8 lb at the entered price per pound

Actual coverage(A/m_plan)Pass25.2ft²/lb

coated area divided by powder to plan

Net coverage before setup(A/m_net)27.8ft²/lb

coverage before setup waste allowance

Theoretical coverage(A/m_dft)42.7ft²/lb

ideal dry film only, before transfer loss and setup waste

Net fresh powder used(m_net)18.01lb

Dry film powder mass(m_dft)11.71lb

Method notes 3 notes
  • Dry film mass = area x film thickness x powder density, with density = SG x 1000 kg/m3.
  • Transfer efficiency is first-pass powder on the part; reclaim is applied only to overspray.
  • This is a powder material estimate only. It does not include pretreatment, masking, cure energy, labor, racks, rejects beyond setup waste or minimum-order pricing.

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