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)
19.81 lb
Pass

net fresh powder plus setup waste allowance

Also computed

Powder material cost (Cost) Pass 158.47 $

uses 19.8 lb at the entered price per pound

Actual coverage (A/m_plan) Pass 25.2 ft²/lb

coated area divided by powder to plan

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

coverage before setup waste allowance

Theoretical coverage (A/m_dft) 42.7 ft²/lb

ideal dry film only, before transfer loss and setup waste

Net fresh powder used (m_net) 18.01 lb

Dry film powder mass (m_dft) 11.71 lb

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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