Typical proven robotic applicators used for seam sealing an automobile are extrude, stream, shower, spray, slit nozzle and brush applicators. The authors propose the use of a swirl applicator to reduce the sealant usage while maintaining the performance requirements of the sealant in certain applications. Several tests were divised to compare the different applicators. The tests identified the amount of the material required by each applicator to seal gaps, seams and holes. The test results showed that overall, the swirl applicator is capable of significant weight savings and delivered more aesthetic beads.