In this paper we present how a normal pressure nozzle can be adapted into a successful electrostatic assisted atomiser for one particular industrial application. The ＇＇Reverse Modelling＇＇ technique for the design of the nozzle head, induction electrode and counter ＇wetting＇ electrode using finite element method is of universal value and can be used widely in induction charging electrostatic spraying applications where wetting is a problem. Experimental results showed that under the same operating condition, an optimised geometry and position of electrodes can give a spray current an order of magnitude higher than the previous design without any wetting problem. An optimum combination of an induction and a counter electrode geometry and positions will ensure a non-wetting induction nozzle assembly with very high charging efficiency.