Powder Coating Coverage Calculator

Estimate powder to buy and its material cost for cut parts. Use the total coated surface area, the powder data sheet, and transfer efficiency from your shop records.

Coating inputs

Inputs are editable examples. Replace them with your job measurements and shop records.

Sum every face and piece being coated. Include both sides when needed.

Use the powder manufacturer's technical data sheet.

Share of sprayed powder deposited on the part, from your process records.

Editable example price; replace with your actual supplier quote.

Powder estimate

Powder to buy
1.0301 lb
Powder cost
10.3 USD
Deposited powder
0.4682 lb
Practical single-coat coverage
21.358 ft²/lb

Coverage includes the entered transfer efficiency, but excludes extra allowance and coat count. Purchase weight includes both. Cost covers powder only, before shipping, tax, labor, curing, masking, and minimum order charges.

  • Uniform dry film and equal thickness for every coat are assumed. Enter transfer efficiency and specific gravity from your own process and powder data.

Method

Sum all coated faces across all pieces, including both sides of flat panels when appropriate. Enter dry-film thickness per coat and the powder's specific gravity. Transfer efficiency is the fraction of sprayed powder that deposits on the parts. The tool first calculates deposited mass, then divides by transfer efficiency and adds your extra allowance. Equal coats share the entered powder properties; calculate different base and clear powders separately.

Deposited kg = coated area (m²) × thickness per coat (µm) × specific gravity × coats ÷ 1,000. Purchase kg = deposited kg ÷ (transfer efficiency ÷ 100) × (1 + extra allowance ÷ 100). Single-coat practical coverage (m²/kg) = 1,000 × (transfer efficiency ÷ 100) ÷ [thickness (µm) × specific gravity]. 1 ft² = 0.09290304 m²; 1 mil = 25.4 µm; 1 lb = 0.45359237 kg.

Worked example

For 20 ft² total coated area, one 3 mil coat, specific gravity 1.5, 50% transfer efficiency, and 10% extra, deposited powder is about 0.2124 kg and purchase weight is about 1.0301 lb. At an illustrative 10 USD/lb, powder cost is about 10.30 USD. Replace these editable example values with your actual process records and supplier quote.

Limits

The result is powder material quantity and cost, not a full coating quote. It excludes minimum pack sizes, stock already on hand, shipping, tax, pretreatment, masking, labor, curing energy, and rejects. Complex geometry, reclaim practice, grounding, and film variation can change actual consumption. Use the product data sheet and measured transfer efficiency; do not treat the example settings as an approved coating specification.