What to do if the edge of the paint is thick when using an air electrostatic manual spray gun
What to do if the edge of the paint is thick when using an air electrostatic manual spray gun
If the **edges of the paint film are too thick** when using an **air electrostatic manual spray gun**, you can adjust several **gun settings, spraying techniques, and environmental factors** to ensure a more uniform coating. Here’s how to fix the issue:
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### **1. Adjust Electrostatic Settings**
✅ **Lower Electrostatic Voltage (kV)**
– **High kV (>80kV)** increases **edge buildup** due to excessive electrostatic attraction.
– **Reduce to 50-70kV** for a more balanced charge and better film uniformity.
✅ **Increase Gun-to-Part Distance**
– If the gun is **too close**, the powder accumulates quickly on edges.
– Maintain a **consistent distance (8-12 inches)** from the part.
✅ **Use a Controlled Grounding System**
– Poor grounding **increases the Faraday cage effect** and causes uneven coating.
– Ensure the **part is well-grounded** with a clean, **low-resistance** connection.
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### **2. Optimize Spray Technique**
✅ **Use a Sweeping Motion**
– Move the spray gun **evenly across the surface**, rather than focusing on one area.
– Avoid staying too long on edges, which leads to excess buildup.
✅ **Adjust Gun Angle**
– **Hold the gun at a 45-60° angle** to avoid excessive edge coating.
– **Do not spray directly at the edge**; instead, let the overspray naturally cover it.
✅ **Reduce Overlapping Passes on Edges**
– Overlapping too much on edges causes thickness buildup.
– Apply **more coats to flat areas** and **lighter passes on edges**.
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### **3. Modify Air & Powder Flow Settings**
✅ **Increase Atomizing Air Pressure**
– **Low air pressure = thicker edge buildup** due to poor atomization.
– Increase **air pressure (30-50 psi)** to **break up the powder/paint particles more evenly**.
✅ **Reduce Powder Flow Rate**
– **High powder output = thicker coating on edges**.
– Reduce flow rate to avoid over-application, especially on thin edges.
✅ **Use a Wider Fan Pattern**
– A **narrow fan pattern concentrates powder on edges**, increasing thickness.
– Adjust to a **wider spray fan** for more even distribution.
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### **4. Adjust the Workpiece Position & Racking**
✅ **Tilt or Rotate Parts if Possible**
– Position edges **at an angle** to **reduce direct powder attraction**.
– Use **custom racks or jigs** to optimize part orientation.
✅ **Increase Part Separation**
– **Too close = electrostatic interference** between parts.
– Maintain adequate spacing to **prevent excessive attraction at edges**.
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### **5. Check Powder Type & Curing Process**
✅ **Use a Powder with Better Flow Characteristics**
– Some powders **naturally build up more on edges** due to their charge properties.
– Consider switching to a **low-build or better-levelling powder formula**.
✅ **Monitor Curing Conditions**
– **Over-curing** can cause edge thickening due to uneven flow.
– Ensure the **oven temperature is uniform** and suited for the specific powder.
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### **Final Solution Summary**
🔹 **Reduce kV (50-70kV) & increase gun distance (8-12″)**
🔹 **Use a sweeping motion & avoid excessive edge passes**
🔹 **Increase atomizing air pressure & reduce powder flow**
🔹 **Adjust part positioning & spacing on racks**
🔹 **Check powder type & curing temperature**
Would you like recommendations for specific **spray gun settings** based on your equipment model? 🚀
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