Practical Guide
Efficient Filler Spraying with the SATAjet X 5500: HVLP vs. RP Compared
Filler application determines the final finish. The SATAjet X 5500 offers two proven technologies with HVLP and RP for different requirements. This practical guide shows when each variant scores, which reference values have proven effective, and how to apply filler layers efficiently and with minimal material waste.
HVLP vs. RP for Filler Application
| Technology | Filler Use | Core Advantages |
|---|---|---|
| HVLP | Fine filler layers, putty, primer | Very material-efficient, low overspray, even layer thickness |
| RP | Fast filler application, large areas, thick layers | High material throughput, quick area performance, powerful spray |
| X Nozzle System | Adjustment to filler type and application technique | I = compact for edges/details, O = wide for surfaces |
Material Efficiency
HVLP: up to 15% less consumption with fillers
Area Performance
RP: 20–30% faster on large filler surfaces
Layer Thickness
HVLP: more even, RP: thicker application possible
Pro Tip:
For putty: HVLP with I-pattern for precise edges, then O-pattern to close. For large surfaces: RP with O-pattern for fast, even application. Always test on a sample surface.
Reference Values for Filler Application
Always check the material data sheet. Values are starting points and may vary depending on filler type/temperature.
| Setup | HVLP | RP |
|---|---|---|
| Inlet Pressure | approx. 2.0–2.2 bar | approx. 2.2–2.5 bar |
| Nozzle Size (X) | 1.3–1.5 (I for edges, O for surfaces) | 1.4–1.6 (I for details, O for surfaces) |
| Spray Distance | approx. 15–20 cm | approx. 18–22 cm |
| Layer Thickness | Even, 2–3 passes | Thicker layers, 1–2 passes |
Note: Values are guidelines; check inlet pressure (digital/manometer).
Filler Workflow (5 Steps)
- Prepare substrate: clean, degreased, correct grit; check adhesion primer.
- Choose technology: HVLP for fine layers, RP for fast area performance.
- Test spray pattern: I for edges/details, O for large surfaces; spray test panel.
- Apply filler: even passes, 60–70% overlap; edges first.
- Intermediate sanding per TDS; if needed, further filler coat; final layer thickness check.
Troubleshooting Filler Application
Uneven Layer Thickness
- Keep pace consistent, increase overlap.
- Test O-pattern for more even application.
- Slightly increase pressure, adjust distance.
Filler runs/sags
- Reduce layer thickness, apply several thinner passes.
- Increase distance, increase pace.
- Check/adjust viscosity per TDS.
Edges not properly covered
- I-pattern for more precise edge coverage.
- Reduce distance, slightly increase pressure.
- Rework edges separately with smaller nozzle.
Too much Overspray
- Prefer HVLP or lower pressure.
- Optimize distance, keep air dry/oil-free.
- Improve booth extraction/airflow.
Maintenance (for Consistent Filler Quality)
- Thoroughly flush after each use; clean nozzle/needle.
- Regularly check seals and air cap; replace if needed.
- Lightly lubricate moving parts; maintain threads.
- Keep filters/couplings/hoses tight and dry.
- Store dust-free, dry; protect cap from impacts.
FAQ Filler with the SATAjet X 5500
HVLP or RP for filler?
HVLP for fine, even layers; RP for fast area performance and thicker coats.
Which nozzle for putty?
1.3–1.5 (HVLP) or 1.4–1.6 (RP) as starting point; I for edges, O for surfaces.
How do I avoid runs?
Reduce layer thickness, apply several thinner passes; increase distance, increase pace.
What overlap for fillers?
60–70% as starting value; adjust depending on filler type and desired layer thickness.
Is the digital version worthwhile?
Yes, very helpful for precise inlet pressure on sensitive filler layers.
Conclusion
The SATAjet X 5500 offers two proven technologies with HVLP and RP for efficient filler application. HVLP excels with fine, material-saving coats, RP with fast area performance. The X nozzle system enables precise adjustment to filler type and application technique.
