How Do You Know When an Airless Spray Tip Is Worn?
Wear reduces spray quality and wastes material. No matter how carefully you maintain your gear, every spray tip will eventually wear out. Here’s how to spot the signs early and replace on time to protect finish quality, costs, and your reputation.
Why Worn Tips Cost You More
As a tip wears, the orifice enlarges and the fan width narrows. You end up making more passes with a smaller fan while pushing more material through the tip—so jobs take longer, finishes look worse, and material usage climbs.
Example: How Wear Impacts Fan Width & Material Output
The table below shows a typical pattern of wear for an airless spray tip. As the fan narrows, output climbs—doubling your passes and your paint use at the “worn” stage.
| Tip Condition | Fan Width | Material Output |
|---|---|---|
| New | 30 cm | 0.90 l/min |
| Used | 27 cm | 1.15 l/min |
| Heavily used | 21 cm | 1.45 l/min |
| Worn | 15 cm | 1.75 l/min |
Values are for illustration only; actual numbers vary by tip size and coating type.
The Cardboard Test
A quick way to check tip wear is to spray a short burst onto a clean piece of cardboard. Compare the fan width and pattern shape to a new tip of the same size. If the spray pattern is noticeably smaller, more rounded, or diamond-shaped, or if the fan width has reduced by roughly 25%, it’s time to replace the tip.
Red Flags That Mean “Replace the Tip”
- Diamond-shaped spray pattern: As the orifice enlarges, the pattern shifts from a soft rectangle toward an oval/diamond.
- Fan width reduced by ~25%: When a 10 cm fan shrinks to around 7–7.5 cm, swap the tip.
- More overspray and bounce-back: You’re pushing extra material to cover the same area.
- Uneven finish or “tiger striping”: A narrowing fan can cause visible banding.
From left to right: the spray pattern and fan width of a new tip, a used tip, a heavily used tip, and a worn tip.
What Causes Spray Tip Wear?
- Excessive pressure: Spray at the lowest pressure that still delivers an even pattern.
- Unstrained material: Use strain bags to remove grit and clumps.
- No filter or wrong filter: Match mesh size to your material and pump specs.
- Old or dirty hoses: Flush regularly; replace aging hoses to maintain consistent pressure.
How to Extend Tip Life
- Use the lowest effective spray pressure for your coating.
- Strain all materials and maintain proper gun and pump filters.
- Flush after use; don’t let coatings cure in the lines or tip.
- Replace tips before pattern and fan width drop significantly.
Recommended TriTech Replacements We Stock
- T93R Contractor Series: 145 fan width/orifice combinations for a perfect match to any coating.
- T93R Maxx Series: 7500 PSI max pressure for high-demand spray jobs.
- T93R Sharp Liner Series: Designed for crisp line striping with minimal overspray.
- T93R Ultra Finish Professional Series: Double-orifice design for ultra-fine finishes.
- T93R Wide-Fan Series: Wide patterns for high-production “blow-and-go” jobs.
Bottom Line
Don’t try to “stretch” a tired tip. Replace early to keep your fan width stable, control material usage, and deliver a clean, even finish—every time.
Get Expert Help & Order TriTech Tips
Need help choosing the right replacement tip? Our team will match you with the right one for the job.