Steel shot is another type of media that can be used. It is made by casting small steel beads according to SAE standard sizes ranging from S-70 (~0.125mm screen size) to S930 (~3mm screen size). There are also multiple hardness ranges, which go from a hardness of 40 Rc up to 62 Rc. The hardness and density of steel shot make it highly durable and in many cases enable it to be re-used for hundreds of cycles! The most common uses for this type of media are cleaning, de-rusting, stripping, and shot peening applications. Metal surfaces can be stress-relieved and hardened to prevent metal fatigue when shot peened using steel shot media.
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Steel shot is best used for heavy-duty applications and materials such as steel and cast iron; it is not generally suitable for softer metals or plastics.
Aluminum Oxide is a tough and abrasive grit media with an angular shape and is often used as a substitute in the sand blasting process. Due to its hardness and angular shape, it is effective at quickly cutting into and etching even the hardest materials. It is often used to prepare surfaces for paint, round sharp edges, and provide a consistent-looking finish. The roughness of the finish will generally correlate to the grit size used. Larger-sized grit will etch the surface more quickly and leave a rougher finish, while finer grits will leave a smoother finish with longer processing times.
Surfaces blasted with aluminum oxide will attain a consistent matte finish with a dull appearance. Aluminum oxide is generally brown in color and can cause some discoloration. Aluminum oxide can be used prior to anodizing to produce uniformly matte anodized parts. It is not suitable for applying finishes to plastic parts.
While there are multiple types of plastic blasting media, the most common and widely used is called Urea. It is made of angular-shaped grains of recycled plastic materials. Being plastic, it is much more gentle than most other abrasives, highly re-usable, and lightweight. This makes it ideal for use on delicate parts or materials without causing damage. Blasting equipment can accelerate the lightweight plastic particles to high velocities, making it effective at quickly stripping light coatings. Plastic blast media is also helpful for de-flashing and deburring operations for molded parts.
While plastic media such as Urea is excellent for cleaning and stripping applications, it is not a good option for achieving cosmetic finishes since the media does not dimple the surface like other types of media.
From the wide selection of available media to the applied pressure and technique, many variables can influence the appearance of your bead blast finished parts. Suppose you are looking to achieve a particular finish. In that case, it is essential to provide specifications to control some of these variables to guide the intended result. When striving for consistent results across production runs or multiple batches, specifications are critical.
When ordering bead blasted parts through Xometry's Instant Quoting Engine, if no further instructions are provided, we will defer to using glass bead media and sufficient pressure to remove tool marks and smooth the surface without damaging the part. The sections below go over tips and best practices you can incorporate to achieve greater control of the process and more predictable and consistent bead blast finishes.
The type of media or abrasive used will significantly influence the look and feel of your finish. For instance, fine glass beads will produce a consistent, satin-like finish, whereas aluminum oxide will yield a uniform but duller appearance. It may take some experimentation to determine what media works best for your project, but you will want to include that information in your order or part drawings notes section once you do. In addition to the type of media, be sure to specify its shape if there are multiple options to choose from.
Another variable that plays a role in how your finish comes out is the particle size of your chosen media. Suppliers often refer to the abrasion grade or grit. The grit is very similar to what you would find when shopping for sandpaper at your local hardware store. The lower the grit, the larger and more coarse the particles are. On the other hand, higher grits will be of finer particles. Mesh size is often referred to as well. The easiest way to understand mesh size is if you were to observe a 1"x1" screen made up of equally sized holes. With a mesh size of 20, there would be 20 holes in the screen, and particles smaller than those holes will pass through, while larger ones will be blocked. With a mesh size of 200, there would be 200 holes in the same 1"x1" area, and thus would be much smaller and only allow finer particles to pass through.
Media size is typically broken down into coarse, medium, fine, and very fine grades. Calling out a grade will simplify your notes and prevent being overly specific, which can limit a manufacturer's options.
By the nature of the blasting process, the part's surface roughness will be directly impacted. It can be challenging for shops to maintain tight surface roughness requirements while also applying a media blasted finish. When these requirements mix, it is often the case that a shop will want to pause the project and get clarification on what the expectations are.
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We recommend limiting surface roughness to no lower than 32 µin Ra when you need a smooth bead blasted part. We do not recommend blasting surfaces that must be lower than 32 µin Ra and instead call out for masking on just those surfaces. Take note that masking requirements can significantly increase labor time and thus cost.
A boundary sample can be invaluable for manufacturers when producing a finish that meets expectations. If your project has strict finishing criteria or detailed notes, a boundary sample can help resolve concerns and provide clarity. Manufacturers can use their knowledge and expertise to produce an output that matches provided examples, reducing the need for detailed notes. If a physical sample is not available, the next best thing would be high-resolution photos taken at various angles. Xometry's engineers and case managers can help you make such arrangements with our manufacturers after placing your order.
Lastly, we recommend including masking notes if your part has any critical features or surfaces that should be guarded against abrasion. Examples of these features are sealing surfaces and o-ring grooves. Although most shops already do this per shop practice, we recommend adding masking requirements for threaded features, especially for small or fine pitch threads.
Sandblasting is a popular technique used to clean, strip, and shape various surfaces by propelling abrasive media at high speeds. The effectiveness of sandblasting depends significantly on the choice of blasting media, which can impact both the finish quality and the overall cost of the process. With numerous options available in the market, selecting the right sandblasting media can be a daunting task. This comprehensive guide aims to assist you in making informed decisions when purchasing sandblasting media in .
Before diving into the specific types of sandblasting media, it’s essential to understand the basic factors that influence their effectiveness. The most critical factors to consider when selecting sandblasting media are:
Now that you have a basic understanding of the factors influencing sandblasting media performance let’s explore the most common types available in the market:
Glass beads are a popular choice for achieving a smooth and bright finish on various surfaces. They are gentle enough for use on delicate materials like aluminum and stainless steel, making them ideal for automotive and aerospace applications. Glass beads are also reusable and environmentally friendly.
Aluminum oxide is a hard and sharp synthetic media, ideal for aggressive cleaning, deburring, and surface preparation. It is commonly used for etching glass and removing rust, paint, or scale from steel surfaces. Aluminum oxide is also highly reusable, contributing to its cost-effectiveness.
Silicon carbide is the hardest sandblasting media available, making it suitable for aggressive and rapid material removal. This media is ideal for applications such as stone engraving, cleaning engine parts, and removing heavy rust and paint. Due to its high cost, silicon carbide is generally reserved for specialized applications.
Crushed glass is an eco-friendly abrasive media, made from recycled glass bottles. It offers a good balance between aggressiveness and gentleness, making it suitable for a wide range of applications, including removing rust, paint, and graffiti. Crushed glass is a single-use media, which may increase the overall cost of sandblasting.
To select the most suitable sandblasting media for your application, consider the following factors:
Choosing the right sandblasting media is crucial for achieving optimal results and minimizing costs. By considering factors such as surface material, desired finish, cost, environmental impact, and availability, you can select the best media for your specific needs. Don’t forget to purchase from a reputable supplier, consider bulk buying, and stay informed about industry trends. With the right knowledge and resources, you can make well-informed decisions for your sandblasting projects in and beyond.
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