Spatially resolved drop size, velocity, and volume flux data for five different spray coating guns were described in this study. Such spatially resolved measurements show how sprays respond to changes in operating conditions and gun design in ways that less complete measurements can not provide. Data for instance, allow us to recognize the unique drop size distribution of one of the sprays tested, which ultimately was an important factor in determining the dual roles of the shaping air flows: depending on drop size, viscosity, and the magnitude of the shaping air velocity, the shaping air can either pinch or induce secondary atomization to the sprays. When the former outweighs the latter, a dumbbell‐shaped spray develops; a more uniform spray results when the opposite occurs. Volume flux data from the different sprays also suggest that a more robust and consistent tablet coating process can likely be designed by utilizing multiple overlapping round sprays. © 2011 American Institute of Chemical Engineers AIChE J, 2012