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What does overspray cost you per part?
Enter your part, your powder price, and your coater's deposition efficiency. The calculator shows powder purchased vs powder deposited — and what every efficiency point is worth at 2026 prices.
Your part & process
Published HVOF norm: 45–55%. Inside bores, radial-injection systems often run lower. Spraywerx measures 70%+ on the axial-injection ID-Nova platform under documented conditions (Spraywerx measured, data on request). If your coater can't tell you their measured DE, that's an answer too.
Optional — scale and comparison
Powder is only part of an HVOF price — labor, gas, and machining add to it — so treat the comparison as a floor, not a quote.
The math on your part
—kg deposited
coating mass your part actually keeps
—
kg powder purchased at your DE
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powder cost on this part (before labor & gas)
| Deposition efficiency | Powder purchased | Powder cost / part | Relative |
|---|
At your annual volume:
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What efficiency is worth on this part:
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difference between your DE and 70% (Spraywerx measured, data on request) — per part, powder alone.
Against what you pay today:
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Same part, different chemistry:
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Get this measured on your actual part — free 15-min scoping call
Substitution is a wear-mode decision, not a price decision. Above ~450–500°C the carbide oxidizes anyway; ambient abrasion and qualified aerospace work stay on WC-CoCr. Check the Powder Selection Matrix before re-specifying anything. 2026 Powder Economics Briefing.
Run this again with different numbers: spraywerx.com — or book a free 15-minute scoping call to have it measured on your actual part: prototyping.html · Spraywerx Technologies Inc., North Vancouver BC, +1 (604) 306-2061
Assumptions, stated so you can challenge them: deposited mass = coated area × as-sprayed thickness × coating density (density presets are typical for dense HVOF coatings of each family); powder purchased = deposited ÷ DE; bore area = π × ID × length (ends excluded). The calculator ignores labor, gas, masking, and machining — all real, all additive, none change the DE arithmetic. Every point of deposition efficiency is purchased powder you don't buy.