6 Best Sprayers for Polyurethane (Tested & Reviewed in 2024)

Spraying polyurethane is one of my favorite ways to apply wood finish for a few reasons. It’s easy, fast, and can deliver a smooth finish with ease.

The best spray guns for polyurethane will feature an efficient and lightweight design that can deliver an even coat of polyurethane on your wood.

In this guide, I’ll help you find the absolute best spray gun for polyurethane so you can spend less time searching and more time working.

In a hurry? The Wagner Spraytech 520008 is the best spray gun for polyurethane because it’s extremely efficient, easy to handle, and much more affordable than other high-quality sprayers.

Quick Answer: Here are My Favorites! 👇

Best Polyurethane Sprayers

• #1 Best Overall – Wagner Spraytech 520008
• Best Quality – HomeRight HVLP Paint Sprayer
• Best Cordless – Graco Ultra Cordless Airless Handheld Paint Sprayer
• Best Value – Astro Pneumatic Tool 4008 Spray Gun
• Most Powerful – Titan FlexSpray Paint Sprayer
• Best Gravity Feed – Campbell Hausfeld General Purpose HVLP Paint Spray Gun

1. Wagner Spraytech 520008 – #1 Best Overall

The Wagner Spraytech 520008 is an incredibly efficient and lightweight polyurethane sprayer that’s easy to use and clean, and it’s cheaper than polyurethane spray guns of similar quality.

A mostly-plastic, electric-powered system, it’s ideal for midsize workpieces (decks, fences, etc.) because it can sufficiently coat a 8’ x 8’ surface in just one minute!

Wagner claims it can apply paint, stain, or polyurethane five times faster than a brush, and I’ve confirmed this a handful of times.

And, of course, you won’t get any brush marks!

This polyurethane spray gun is also easy to adjust. Specifically, you can adjust:

• Spray pattern (horizontal or vertical)
• Width (wide or narrow)
• Flow control (more or less)

Disassembling the tool for cleaning takes no time at all once you get the hang of it, and I definitely like that you can thoroughly clean all the important components without much hassle.

The nozzle it comes with can be swapped out for other Wagner nozzles of similar size, and its capacity is 1.5 quarts.

Fully loaded, it can sufficiently cover up to 125 sq ft, depending on the surface’s porosity.

Finally, it comes with a two-year limited warranty that covers defects related to materials or workmanship.

What I Liked:

• Its responsive flow-control feature makes it easy to apply the right amount of poly every time.
• It’s equipped with a reliable turbine to ensure steady flow at any setting.
• It has more capacity than other sprayers, so it can cover a larger area in less time.
• It’s ergonomic, compact, and lightweight, so it’s easy to maneuver.

What I Didn’t Like:

• It’s more prone to impact damage since it’s mostly plastic.
• It has to be thoroughly cleaned after every use or else it won’t be as efficient later on.

2. HomeRight HVLP Paint Sprayer – Best Quality

If superior control, large capacity, and precise results are all important to you, I highly recommend the HomeRight HVLP Paint Sprayer.

A high-volume, low-pressure system, it comes with three brass spray tips (1.5 mm, 2.0 mm & 4.0 mm) to ensure versatility. Three other HomeRight spray tips work on it, but these are sold separately.

Unlike other systems, it utilizes to air caps to ensure better flow control; I’m a big fan of this since control is crucial when spraying.

Its spray-width range is 1”-12”, and it has a very attractive 40-ounce tank; a full tank can sufficiently cover a surface that’s 10’ x 10’.

The absence of a compressor means this 450-watt, airless paint sprayer is neither noisy nor jumpy, and its three pattern settings are: Horizontal, Vertical, and Cone.

An innovative pickup tube and cup vent are employed to boost efficiency, and it can spray both water-based and oil-based materials.

As far as dimensions go, it’s 9.5” x 6” x 12.5” and weighs just 3.3 lbs.

Finally, this airless paint sprayer comes with a container lid, wrench, spray nozzle, and cleaning brush. Additionally, a two-year limited warranty is provided.

What I Liked:

• Its substantial capacity allows you to spray larger surfaces completely without needing to reload.
• No air compressor means it’s easier to spray in an uninterrupted motion.
• Its brass spray tips last a long time and ensure precise spray width.
• It’s great for DIYers since it’s simple, efficient, and easy to clean/maintain.

What I Didn’t Like:

• Too many plastic parts make it vulnerable to impact damage.
• It’s prone to clogging if the material hasn’t been properly thinned beforehand.

3. Graco Ultra Cordless Airless Handheld Paint Sprayer – Best Cordless

Don’t want to deal with a cord when spraying polyurethane? Then you need the Graco Ultra Cordless Airless Handheld Paint Sprayer, as it’s one of the most capable and reliable cordless spray guns available right now.

For starters, it has a Triax II Triple Piston Pump, and this not only makes it more durable but more efficient too.

SmartControl tech is employed to ensure there are no pressure fluctuations when you’re spraying, and this is big for me since I take my time when spraying polyurethane.

It takes RAC X FF LP spray tips, and these ensure the spray width and pattern are both extremely accurate. They can also unclog themselves, which I find pretty neat.

A DeWalt 20V battery is its power source, and it can spray about a gallon on a full charge.

Its FlexLiner Paint Bag can hold 32 oz of material, and it’s easy to clean because it employs disposable liners and there’s no suction tube.

As far as specs go, its minimum working PSI is 500, while its max working PSI is 2,000.

It’s 14” x 5” x 10.5” and weighs about 5 lbs, and it can accommodate tips that are 0.008”- 0.016”.

A tip guard, mesh filter, and storage case are included when you purchase this spray gun, and it comes with two three-year limited warranties: one for the tool and one for the battery.

What I Liked:

• No need to thin oil-based poly before spraying since this spray gun can unclog itself. 
• Easy to control spray pattern and width thanks to a reliable control knob.
• The DeWalt 20V battery ensures you spend more time spraying and less time charging.
• The thorough manual will help you use, clean, and maintain it properly.

What I Didn’t Like:

• Much more expensive than most corded spray guns.
• Replacement parts can be difficult to get.

4. Astro Pneumatic Tool 4008 Spray Gun – Best Value

The Astro Pneumatic Tool 4008 Spray Gun is a fantastic paint sprayer for those on a tight budget, as it’s effective, versatile, easy to use, and sold at a fraction of what other quality paint sprayers cost.

This two-piece, aluminum paint sprayer has an operation pressure range of 50-60 psi, and it can apply a quart of paint, polyurethane, stain, etc.

Its air inlet thread NPT is 1/4”, and it’s equipped with a 1.8 mm nozzle.

You’ll need a 3 HP air compressor to operate it, and its spray width range is 1”-11” from an 8” distance.

As far as special features go, it has an anti-spill air feed line, and I like this because it ensures you get consistent pressure regardless of how the sprayer is held.

One of the lighter paint sprayers, it weighs just 3 lbs, I can operate it with one hand for an extended period and not feel any discomfort.

Its width is 6-1/2 and its height is 12”, so it’s definitely better at vertical spraying.

Additionally, it comes with a thorough user manual so the inexperienced can operate it just as well as the experienced.

And like the vast majority of paint sprayers, it comes with a warranty—a one-year limited warranty to be exact! Pretty cool for an already affordable product.

What I Liked:

• Its aluminum components add weight and make spraying in a continuous motion easier.
• Its anti-spill feed line makes it ideal for spraying ceilings and other overhead surfaces.
• Its compact size and smaller capacity make it ideal for painting furniture.
• Its detailed manual and low price make it a great buy for those who’ve never sprayed poly before.

What I Didn’t Like:

• Its upright shape can make spraying horizontally awkward and inaccurate.
• Its air volume control is a little sensitive, and this can cause unintended changes.

5. Titan FlexSpray Paint Sprayer – Most Powerful

If you want more power from your polyurethane sprayer without sacrificing efficiency, I suggest taking a long, hard look at the Titan FlexSpray Paint Sprayer, as it’s one of the most powerful polyurethane sprayers I’ve ever had the pleasure of using.

Equipped with a four-stage turbine, this airless paint sprayer can stand toe to toe with the best HVLP spray guns, and its versatility is one of the main reasons why I and so many others enjoy it.

It can spray thick and thin paints, stains, and polys with ease, and it’s relatively easy to clean once you’re familiar with disassembly and reassembly.

A heavier airless paint sprayer, it employs a stainless steel one-quart cup and other metallic components.

As far as adjustable settings go, you can adjust air power, flow output, spray width, and spray pattern, and all the knobs/switches are responsive and reliable.

It’s 21.56” x 11” x 15.75”, and its max delivery is 0.20 GPM.

When you purchase this HVLP spray gun, you get:

• FlexFinish front end for spraying broad surfaces (1)
• Cleaning brushes (2)
• Shoulder straps (1)
• Air filters (3)
• Cup gaskets (2)
• Nozzle seal (1)
• Practice spray poster (1)

Finally, this airless paint sprayer comes with a one-year limited warranty, and it’s pretty basic in terms of what it covers.

What I Liked:

• It sprays thick, oil-based poly and paint without splattering, so the tedious thinning process is cut out.
• Its adjustable knobs and switches lock firmly in place once set, ensuring accuracy and peace of mind.
• Its evenly distributed weight makes all spraying patterns smoother.
• It comes with a range of useful accessories to ensure it’s always efficient and easy to maintain.

What I Didn’t Like:

• It sometimes drips after the trigger’s released.
• It can stuttered a little bit after several minutes of continuous spraying.

6. Campbell Hausfeld General Purpose HVLP Paint Spray Gun – Best Gravity Feed

Gravity-feed spray guns are pretty effective for a handful of reasons, and the Campbell Hausfeld General Purpose HVLP Paint Spray Gun—with its sleek shape and finely calibrated spray settings—is easily one of the best in its class.

Equipped with a 20 oz canister, aluminum sprayer has an operating pressure of 40 PSI, and it can deliver 4.0 SCFM at this pressure.

Its air inlet is 1/4” NPS, and it works best with a 3/8” hose.

Plus, it’s one of the lighter sprayers—just 2.6 lbs!

Its spray width range is smaller than other sprayers (1.5”-9”), but this isn’t a problem for me because I rarely need more than 6” of spray width.

The nozzle is 1.4 mm, and it can easily pass materials that have a medium viscosity.

And just like on other sprayers, you can adjust airflow, flow output, and spray pattern.

Finally, it comes with:

• In-line paint filters (2)
• Wrench (1)
• 6mm hex wrench (1)
• Cleaning brush (1)
• 1-Year Limited Warranty

What I Liked:

• Its polished aluminum case makes it easier to grip and maneuver.
• Its gravity-feed tank ensures you don’t waste any material.
• Cleaning is simple since there are few components, and both disassembly and reassembly are easy.
• It’s compact and relatively small, so spraying hard-to-reach areas is a breeze.

What I Didn’t Like:

• The metal used isn’t the strongest and can wear down with frequent use.
• The plastic canister is prone to cracking and leaking.

How to Choose a Spray Gun for Polyurethane

Quality & Reliability

A quality paint sprayer is a reliable paint sprayer, so be on the lookout for well-designed sprayers that employ numerous high-quality components, as these are more likely to stand the test of time.

Personally, I like my sprayers to be more metallic than plastic, but I know there are many excellent plastic sprayers out there.

Want to know how to Spray Polyurethane more effectively? Check out the video down below!

Control & Handling

Control is everything on a sprayer. In other words, if you don’t have total control when operating this tool, it’ll be much harder to achieve even, smooth coats in a short period.

Compact, lightweight sprayers with finally calibrated settings are easiest to control and maneuver.

Capacity

Capacity is also important, since sprayers with more capacity get jobs done quicker.

But a lot of capacity doesn’t necessarily mean a sprayer is good; the tank/canister could inhibit the tool if it’s too bulky.

But if you find a sprayer with a larger capacity—and it’s not inhibited because of this—it’s probably a solid buy.

Price & Warranty

Most quality paint sprayers are around $100, but you can find capable, efficient, and reliable products between $50 and $60.

And most sprayers come with some kind of warranty or satisfaction guarantee. And generally speaking, the more expensive and complex the sprayer, the longer the warranty, but this isn’t a hard and fast rule.

Types of Paint Sprayers

Pneumatic Paint Sprayers

These sprayers have been around the longest, and even today they offer a handful of distinct benefits.

For one, they’re still the preferred sprayer for precision work because air pressure is easy to generate, adjust, and cut off.

And since there’s no turbine involved, you won’t have to worry about the sprayer’s power diminishing with age; it’ll always be as powerful as the compressor it’s attached to.

Airless Paint Sprayers

An airless spray gun uses powerful pistons instead of compressed air to release the material, and therefore airless spray guns are generally less wasteful and easier to control.

They’re also ideal for larger surfaces since they can release a lot of material quickly yet steadily.

High-Velocity, Low-Pressure Paint Sprayers (HVLP)

An HVLP sprayer can be pneumatic or airless, and it uses less material because it doesn’t spray with considerable force—like other sprayers.

Essentially, because more material is sprayed under less pressure, it’s easier to achieve a smooth, even surface.

They are, however, more expensive than conventional spray guns.

FAQs

What kind of sprayer should I use for polyurethane?

Whether you’re using oil-based or water-based polyurethane, it’s best to choose an airless sprayer. These are generally more powerful, so they can apply a smooth, protective coat quicker and with less hassle.

Does polyurethane need to be thinned to spray?

If you’re using a viscous, oil-based polyurethane, it’s best to thin it before loading your polyurethane sprayer. Water-based polyurethane is thin as it is, so it can be loaded into the sprayer without alteration.

What is the best nozzle size for polyurethane?

The best nozzle sizes for polyurethane are: .013 mm, .014 mm. and .015 mm. Since polyurethane is thicker, a larger nozzle is required. Latex paint, on the other hand, doesn’t need a large nozzle because it’s much thinner.

Can you spray polyurethane with an airless sprayer?

Yes, you can spray polyurethane with an airless sprayer. In fact, using an HVLP sprayer is arguably the best way to spray water-based and oil-based polyurethane. Since there’s no air pressure involved, applying an even, bubble-free surface is easy, and you don’t have to worry as much about clogging.

Final Thoughts

To recap, the Wagner Spraytech 520008 is the superior polyurethane sprayer because it delivers in all the ways a spray gun is supposed to deliver, yet it’s hundreds of dollars less than comparable products.

For superior control and substantial capacity, the HomeRight HVLP Paint Sprayer will serve you well.

And if staying within budget is your highest priority, consider the highly capable and reliable Graco Ultra Cordless Airless Handheld Paint Sprayer.