Spray guns with a 2,5 mm nozzle

The 2.5 mm nozzle is the largest size in standard use on spray guns. It is intended for extremely thick coatings, textured finishes, spray putties or compounds containing fibre and filler. It allows rapid application of heavy layers over large areas in industry, construction and when repairing technical equipment.

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When to use the 2.5 mm nozzle

The 2.5 mm nozzle is the ideal choice when smaller diameters are no longer enough. It is used above all for applying:

• spray putties – including polyester and fibre-filled versions,
• gel coatings and thixotropic compounds,
• insulating materials with a high solids content (bitumen, rubber or PVC based, for example),
• protective coatings containing filler or microfibre.

Thanks to the large nozzle diameter, the gun applies a heavy layer of paint or filler quickly, with no snagging or pulsing. The material passes through the nozzle smoothly and covers intricate or less prepared surfaces that need levelling with a thicker layer.

Typical examples of use

• Structures and large steel surfaces: suitable for spraying anti-corrosion coatings on masts, frames, containers or industrial halls.

• Vehicle underbodies and lower parts: for applying protective layers resistant to abrasion and moisture – bitumen or rubber compounds, for example.

• Insulating layers in industry and construction: spraying waterproofing compounds onto foundations, roofs or basement sections of buildings.

• High-build fillers and textured compounds: usable in repairs, filling and surface treatment where maximum covering power is required.

Recommended working pressure

On HVLP guns the typical pressure is around 2.0 bar (inlet); on classic conventional systems 3–4 bar. It is essential to use a capable compressor with sufficient air flow and ideally also a pressure regulator with separator. With the right settings you will achieve a smooth flow even with very thick coatings.

Comparison: 2.2 mm vs 2.5 mm

The 2.2 mm nozzle is often chosen as a compromise between output and spray control. But if you use the thickest materials – fibre-filled, thixotropic or textured – the 2.5 mm nozzle is the clear choice. It allows application without excessive thinning and ensures that even the most demanding materials reach the surface in a sufficient layer.

Alternative uses and recommendations

For ordinary painting (clear top coats, acrylics) the 2.5 mm nozzle is not really suitable – it would build too heavy a layer and waste material needlessly. It is therefore intended purely for technical and protective coatings, where durability and area coverage take priority. If you need advice, the article in our advice section will help you pick the right nozzle and gun.

Recommended range:

👉 Spray guns – for paint shops and tradespeople