Technical Abstract: Experiments were conducted to study the conidial viability during bioassay spray with different suspensions of Metarhizium anisopliae ATCC 62176 and Beauveria bassiana NI8, and to investigate the effects of conidial density and spray volume on the distribution of droplet size and deposit coverage using water sensitive paper (WSP) cards. Results showed there was no adverse effect on the viability of ATCC 62176 or NI8 conidia during the spray regardless of conidial density and spray volume. The interaction between conidial density and spray volume of both fungal species had no effect on droplet size distribution expressed as Volume Median Diameter (VMD) or natural log transformed VMD (ln VMD), and had no effects on droplet coverage of both fungal strain suspensions either. The effects of spray volumes of ATCC 62176 suspensions on the distribution of droplet size and on the droplet coverage were highly significant (P < 0.0001) regardless of the natural log transform and the conidial densities. Conidial density of tested suspensions of NI8 had significant effect on ln VMD and the droplet coverage on the WSP cards (P <0.01). The effects of spray volumes of conidial suspensions of NI8 on the distribution of droplet size and droplet coverage were highly significant (P < 0.0001) regardless of the natural log transform. This is the first to report the effects of conidial density of biocontrol agents on the distribution of droplet size and coverage during bioassay studies. Natural transform provided better models for both droplet size distribution and coverage regardless fungal strains.