Thermal Spray, Hardfacing & Wear Coatings worked example
Coating Thickness Buildup at 99% booth productive-time efficiency: a worked example
What does the result look like when booth productive-time efficiency reaches 99%? The full calculation is worked below with real intermediate numbers. Use it when coating thickness buildup in thermal spray, hardfacing and wear coatings is being committed and you need a throughput number you can defend.
The inputs for this scenario
- Total coated parts completed: 1,200 units (unchanged)
- Spray booth runtime: 8 hr (unchanged)
- Booth productive-time efficiency: 99 % (raised for this scenario; the documented default is 90)
Working through the calculation
- Applying the documented formula (Raw coating thickness buildup = completed output รท runtime) to the inputs above produces each figure below.
- At this operating point the engine returns 149 units for effective throughput, the number this scenario is built around.
- At this operating point the engine returns 150 units for raw throughput.
- At this operating point the engine returns 99 % for efficiency.
- At this operating point the engine returns 8 hr for runtime.
How this compares with the baseline
- Against the tool's baseline example, where booth productive-time efficiency sits at 90% and the headline result is 135 units, this scenario comes in 10% above the baseline at 149 units.
- A figure at this level is achievable when booth productive-time efficiency is genuinely sustained, not just peaked for a shift. It treats all parts as equivalent, so a mix of quick wear coatings and slow multi-pass builds will average out and hide the real variation.
Results at a glance
- Effective throughput: 149 units (headline result)
- Raw throughput: 150 units
- Efficiency: 99 %
- Runtime: 8 hr
Run it with your numbers
- Every input above is editable in the live Coating Thickness Buildup calculator, which recalculates instantly and can be shared with the inputs intact.
Last reviewed 2026-05-12.