Best Airless Paint Sprayer for Polyurethane

By Mego Kimani •  Updated: 05/14/24 •  10 min read

The application of polyurethane has been made many times easier by the existence of airless paint sprayers. The use of this unique innovation makes the application of polyurethane many times easier compared to when using a brush or a roller. With an air sprayer, you are guaranteed several advantages during your application process. For instance, using an air sprayer is faster which means you can complete more jobs in less time. Moreover, the quality of your application is improved as the coat of polyurethane produced on your wooden surfaces is many times more consistent than when using a brush.

Comparison Table

HomeRight Power Flo Pro 2800 C800879Graco MagnumWagner Spraytech 0580678  Himalaya Airless Paint SprayerGraco Ultra Cordless Airless Handheld Paint Sprayer 17M363  
Exterior decks, fencing and sidingLarger surfaces such as floorsExterior large surfaces such as decksBest for professionalsSmall interior and exterior projects
Highest pressure and control Reversible tipsUltimate pressure controlProduces up to 55% less overspray than traditional airless sprayers which means higher efficiencyHigher pressure ratingHand held sprayer

What is an airless sprayer

magnum x 5

An airless sprayer is a type of sprayer that breaks up polyurethane or any other fluid such as paint into tiny droplets. However, unlike in air sprayers, the breakdown or atomization is achieved through the use of a pump and the spray tip. The level of the pressure applied and the size of the tip are what determine the flow rate of the polyurethane or any other liquid such as pint.

HVLP vs airless sprayer for woodworking

HVLPs are different from airless sprayers in that in an HVLP, material or polyurethane atomization or break up into tiny particles is achieved by air pumped from an air compressor. On the other hand, as mentioned above air atomization in airless sprayers is not dependent on air but on the pressurization of the material and the tip size.

Factors to consider when buying an airless paint sprayer

Spray Tip

The quality of the polyurethane coat produced is largely dependent on the size of the spray tip. Technically, the size tip is the size of the orifice that the material is pumped out through. Hence the amount of polyurethane flowing to the surface will depend on tip size. Airless sprayer tips come in a variety of shapes. For polyurethane, the smallest tip size ranging from 0.009-0.015 is suitable. It is necessary to know that the flow rate of the tip must be less than the maximum flow rate of the paint sprayer for optimum functioning. 

Pressure Level

Another key factor that determines the flow of polyurethane onto the surface is the level of pressure the sprayer is set. A higher level of pressure is suitable for specifically larger jobs such as floors, decks, and fences where the control of the coat is not a major concern. However, for smaller projects, a low-level pressure allows for better control of the spray. It is important to note that a change in pressure level should be accompanied by a suitable change in tip and filter.

Filter type

Tips work hand in hand with suitable filters to control the flow rate as desired. These are essential for keeping the tip from clogging since they filter out debris that may be contained in the polyurethane. Fine filters go well with polyurethane since it contains less debris and it is compatible with a tiny tip.

Corded vs. Cordless

Another important consideration is whether the airless sprayer will require you to tether it to the power outlet or not. Corded sprayers are preferable since they came in many options and offer the option of drawing a larger amount of polyurethane from the container as opposed to putting it in a canister. However, these may offer a limited range of movement. 

Best Airless Sprayer for Polyurethane

Graco Magnum 262800 X5 Stand Airless Paint Sprayer

This airless paint sprayer is the best you can get in the market because it combines all the best features in a single item. It is suitably built to achieve an even smooth coating of polyurethane over your wooden surfaces both large and small inside and outside the house.

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Why choose Graco Magnum

Graco Magnum airless paint sprayer meets all the best features such as:


Despite having excellent features, being corded means that it has a limited range of coverage.

Wagner 0580002 Control Pro Paint Sprayer

This paint airless sprayer is regarded by most as the best in its category for enhanced efficiency over HVLP’s and other airless sprayers in its category. Not only does it facilitate a smooth polyurethane coat over your wooden surfaces, but it also comes in large size tank that enables you to coat a larger surface without refilling.

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Why Choose Wagner Spraytech 0580002

Some of the top reasons why this product is regarded among the best and why you should choose it include:


Being a corded sprayer means that this product no matter how long the hose, is limited to the that size. Thus, mobility is limited. Moreover, it comes in an annual spray limit of 500 gallons per year. It is also one of the costliest options on his list.

Himalaya Airless Paint Sprayer (

Why Choose Himalaya Airless Paint Sprayer

The following features make this product one of the best in the market:

Spray Tip: Himalaya Airless Paint Sprayer tip size maxes out at 0.017 inches. This makes it ideal for applying polyurethane which require small tip sizes due to its thin nature. With this sprayer, there is no need to include a thinner to your polyurethane.

Long Hose: the size of the hose for this product is 25 feet. This is good for most surfaces such as floors and patios as long as the outlet is suitably placed. 

Price: this product is very cost friendly compared to other products listed here

Pressure Level: The pressure level of this unique airless sprayer is 0.28 gallons per minute. This pressure level is suitable for the application of polyurethane which is thin enough to not require a very high pressure.


If you require a portable airless sprayer, then this is not ideal for you since it is corded. This limits the area of coverage.

Graco Ultra Cordless Airless Handheld Paint Sprayer 17M363 (

Just as the name suggest, Graco Ultra Cordless is one unique airless sprayer because it comes completely portable. This means that it is not powered from an electrical outlet but with batteries. Thus, this makes it the ideal applicator for more intricate projects such as furniture.

Why you should select Graco Ultra Cordless

Graco Ultra Cordless airless sprayer has several features that distinguish it from others on the list:

Cordless: the first advantage that this sprayer has over the others is that it is cordless. This means that you do not need to tether it to an outlet. This provides you with more freedom when it comes to movement and manageability of your wooden surfaces. You can easily reach hard to access corners and curves for intricate surfaces.

Tip Size: this item come in an ideal tip size of up to 0.017 inches which makes it ideal for applying thin finishes such as polyurethane.

Flow rate: this product come with an ideal flow rate of 0.27 gallons per minute. This is ideal for thin finishes such as polyurethane.

Portable: this item is the most portable on this list. This feature makes it ideal for carrying and moving around when applying pieces such as furniture.


On downside of this item is since it is portable, it comes in a small size tank. This means you will need frequent refilling for relatively larger projects. Another downside is that it is very expensive

HomeRight Power Flo Pro 2800 C800879 (

HomeRight Power Flo stands out in this list because it is the only product that is recommended for exterior use only. This 15-pound item also comes with excellent handling facilities which are ideal for moving it around where you need it.

Why you should choose this item

HomeRight Power Flo has several features that make it appear on this list. This include:

Suitable Tip Size: the tip sizes on this item range up to 10 inches. Large tip sizes such as these are ideal for larger surfaces such as decks, patios and fences that require less intricate application.

Corded: this item like most on the list is corded. Therefore, to make up for it comes with a 25-foot-long hose to increase coverage area.

Pressure level: the pressure rate of this item is a maximum flow rate of 0.24 gallons per minute. This rate is ideal for polyurethane application on external surfaces.

Built-in top handle: A handle at the top of this item is suitably placed to help in lifting and moving the sprayer around to the area where it is needed.


This item has a limited range of coverage area. Moreover, it is bulky and heavy to move around.


Airless paint sprayers are a huge milestone when it comes to the application of polyurethane. Traditional polyurethane application methods such as the use of brushes and rollers are time-consuming and inefficient. With brushes and rollers, the coat produced is uneven requiring more work to achieve evenness. To take care of these problems we highly recommend that you select an airless paint sprayer that suits your needs. These products are carefully selected to take care of a range of needs that suits both experts and normal homeowners looking to overcome the problems of brushing and rolling.

Mego Kimani

Hi there, my name is Mego Kimani, and I am the owner of Woodmeter, a website dedicated to wood finishing. At Woodmeter, we offer a comprehensive resource for woodworkers and DIY enthusiasts, providing information on everything from achieving the perfect finish to product recommendations and technique guides. Our goal is to empower our community with the knowledge they need to create beautiful, long-lasting finishes on their projects, no matter their skill level or experience.