The discriminative power of existing dermal exposure models is limited. Most models only allow occupational hygienists to rank workers between and within workplaces according to broad bands of dermal exposure. No allowance is made for the work practices of different individuals. In this study a process-based, structured approach has been used to estimate dermal exposure from overspray generated by a spray painting process. Factors for spray technique, object shape and workers' individual work practices involved in the processes of droplet formation and deposition were incorporated into the model. The model was applied to predict dermal exposure of airless spray painters and the results were compared with exposure data. The predicted levels of exposure showed reasonable rank correlation with the measured exposure, although the model tended to over-predict the actual level of exposure. It was concluded that a structured, process-based approach has the potential to produce reliable estimates of dermal exposure. The reliability of exposure models of this type should be explored further and the relationship between the determinants of exposure should be validated by additional field studies.