In this blog, we will give a complete introduction to sandblasting, including its definition, its working process, materials, and media. You will have a clear knowledge of sandblasting after reading. Let’s start!
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The history of sandblasting was tracked back to the mid to late 1800’s.
Sandblasting was inspired by natural sand erosion and ancient hand sandblasting techniques, such as the ancient Egyptians’ use of abrasive sand to polish stone.
In 1870, American Benjamin Chew Tilghman patented the first compressed air-driven sandblasting technology under the name “Sandblasting”.
Sandblasting was originally referred to the use of quartz sand as an abrasive surface treatment for industrial metal descaling and glass engraving, primarily for industrial rust removal on metals and decorative glass etching.
In the early 20th century, quartz grit was gradually replaced by man-made abrasives such as steel grit, glass beads, ceramics, etc. due to silicosis. The sandblasting equipment is also improving.
The scope of sandblasting technology expanded greatly, and the terminology evolved to become the broader term Abrasive Blasting.
Abrasive blasting covers all processes that utilize high velocity abrasives, including metal pellets, plastic pellets, ice crystals and even dry ice, to impact surfaces. Sandblasting, on the other hand, is a historical term reserved.
This change reflects the diversification of abrasives,from natural sands to environmentally friendly synthetics.
It also marks the industry’s shift from a single cleaning function to precision surface modification ,e.g., stress-strengthening of aerospace components, while adapting to modern environmental and occupational health and safety standards.
Nowadays, dry blasting,driven by compressed air, we blasting, water mixed with abrasive are well used in high-end fields such as architectural concrete treatment, heritage restoration, and semiconductor wafer cleaning, CNC maching parts.
Abrasive blasting is a core technique that blends historical legacy with technological advancement in modern surface engineering.
Sandblasting is a surface treatment process, sandblaster machine projects high-velocity abrasive particles onto a part surface to clean, roughen, deburr, or reshape it.
From the sandblasting definition, we can see that its core components include:
A: Abrasive material
B: A motive force, such as compressed air, centrifugal force or liquid flow.
C: The purpose is to strip away contaminants (e.g. rust, old coatings) or to change the surface morphology (e.g. to increase adhesion).
Some key points about sand blasting definition.
Historically, sandblasting referred to using natural sand as the abrasive. Later, natural sand has been largely replaced by safer alternatives abrasives such as steel grit, glass beads, ceramic particles, and plastic media.
More accurately, sandblasting shall be named as abrasive blasting, because abrasive materials are more than just sand.
Technically, abrasive sandblasting include dry blasting(air-driven), wet blasting (abrasive mixed with water), and shot peening (used to enhance surface stress profiles).
In CNC machining industry, sandblasting is commonly used to refer to abrasive blasting, even though the actual media may not be sand.
In this blog, we continue to use the term sandblasting as a substitute for abrasive blasting.
The process of sand blasting is mainly divided into five steps, which are described as follows.
Before sandblasting begins, the workpiece needs to be thoroughly cleaned to remove surface oil, grease or loose oxidized layer.
Alkaline degreasing agent is usually used to soak or solvent wipe, if there is heavy rust or oxide skin, may need to be combined with acid washing (such as phosphoric acid treatment of steel) or mechanical grinding for initial cleaning.
Dry the cleaned workpiece completely, avoiding residual moisture which may affect the subsequent blasting results. For areas that do not need to be blasted (e.g., precision threaded holes or assembly surfaces).
They should be protected with abrasion-resistant tape, rubber plugs, or special fixtures to prevent accidental abrasive damage.
Select the right abrasive to different sandblasting materials.
Metal parts commonly use steel or stainless steel shot to improve efficiency.
Aluminum, magnesium and other soft metals will use glass beads or ceramic grit to avoid deformation.
Plastics or composites will use plastic abrasives or walnut shells and other soft particles.
Sandblasting equipment-sandblaster- needs to set the air pressure (dry sand blasting is usually 0.5-0.7 MPa, wet sand blasting can be reduced to 0.3-0.5 MPa), choose wear-resistant nozzles (such as tungsten carbide) and adjust the spray angle (60 ° – 75 ° for conventional cleaning, 90 ° for deep groove processing).
The sand blasting room should be equipped with a closed dust removal system (e.g. cartridge filtration) and protective equipment (air-supply helmet, protective clothing) to ensure safe operation.
We will describe the sandblasting process by manual sandblasting and automatic sandblasting.
By manual sandblasting, the operator should be involved in the whole sandblasting process.
First, the surface of the workpiece is cleaned and areas that do not need to be blasted are covered.
Then the blaster is started up and the air pressure and abrasive reserves are checked.
The operator needs to wear protective clothing and holds a spray gun, blasts the workpiece at the appropriate angle and distance.
After finishing sandblasting, the operator will use compressed air or vacuum equipment to clean up the workpiece residual abrasive, and check the surface treatment effect.
For automatic sand blasting machine, the operator firstly needs to set the program parameters, including injection pressure, nozzle running track, processing time, etc..
After the workpiece is fixed by conveyor belt, turntable or fixture, the system automatically controls the nozzle to carry out sand blasting treatment.
During the blasting process, the surface is monitored in real time, visually inspected for complete removal of contaminants (e.g., Sa 2.5 cleanliness), and a roughness meter is used to spot-check the Ra value (e.g., the Ra of the surface before coating is controlled at 2.5-4.0 μm).
Wet blasting requires additional control of the water-abrasive mixing ratio to minimize dust diffusion.
Remove the residual abrasive dust on the surface of the workpiece after sandblasting,.
Use compressed air blowing or vacuum adsorption to clean the CNC precision parts for dry sandblasting.
Wet sandblasting needs to be rinsed with water and quickly dry to prevent rust.
Abrasive recycling is the key to cost control: metallic abrasives can be recycled through vibratory screening and magnetic separation, while non-metallic abrasives (e.g. glass beads) need to be filtered for impurities and reused.
Inspect the surface quality after sandblasting and remove residual abrasives.
If the workpiece needs subsequent surface treatment, such as painting, anodizing, powder coating, etc., the latter process should be carried out as soon as possible to prevent the surface from re-oxidation or pollution.
The 5 steps above explain how sandblasting works.
Sandblasting has many practical advantages, especially if you’re dealing with metal parts or surfaces that need prep work.
First, sandblasting can remove rust, coatings and dirt from workpieces surface.
Second, it can evenly roughen the surface. A slightly textured surface helps paints or adhesives stick better.
In CNC machining industry, for aluminum parts, we always do sandblasting before anodizing and because of the two advantages mentioned above.
Also sandblasting can remove burrs or sharp edges left from CNC machining.
A lot of materials can be blasted, for example, plastic, stone, or even glass.
We will explain in detail the types of abrasive media and the grit.
There are many sandblasting abrasives types, with different hardnesses, shapes, densities, and applications.
Quartz sand is a traditional abrasive with low price and moderate hardness. In the past, sand is used to remove basic rust and oxide skin. But it was replace by other environmentally friendly abrasives, because sand can cause high dust and health risks.
Aluminum oxide has high hardness and durability and strong cutting power. It can roughen the metal surface, clean the stainless steel and carve the glass. Aluminum oxide is recyclable and is one of the mainstream abrasives in industrial sand blasting.
Glass bead is round, suitable for polishing surface treatment. In aluminum CNC machined parts sandblasting, glass bead is always used before anodizing.
Steel grit and steel shot have high density and strong impact, suitable for heavy-duty rust removal and surface enhancement, such as castings and forgings sandblasting.
Steel grit and steel shot are also recyclable.
Ceramic beads are less abrasive, less dusty, and suitable for fine blasting. For high-end parts such as aerospace parts and medical instruments, ceramic beads can protect the workpiece surface.
Plastic grit is soft,and suitable for removing coatings or cleaning the surface of avionics and composites. It is environmentally friendly with less dust.
Silicon carbide is extremely hard, commonly used in glass, ceramics and carbide. The price is higher, suitable for special high-end process.
Walnut shells and corn cobs are natural organic abrasives. They are soft and environmentally friendly and non-toxic. They are commonly used in cultural relics cleaning and mold surface treatment, can effectively remove dirt without damaging the workpiece.
Abrasive Type | Hardness | Reusable | Dust Level | Typical Applications | |
Metal Abrasives | Steel Grit / Steel Shot | High | Reusable | Low | Heavy-duty rust removal, surface strengthening |
Non-metal Abrasives | Aluminum Oxide | High | Reusable | Medium | Metal roughening, glass engraving |
Silicon Carbide | Very High | Reusable | Medium | Hard materials, precision engraving | |
Glass Beads | Medium | Reusable | Low | Matte finish for stainless steel, precision polishing | |
Ceramic Beads | High | Reusable | Very Low | Aerospace and medical high-end components | |
Natural Mineral Abrasives | Quartz Sand | Medium | Single-use | High | Basic rust removal, paint stripping |
Eco-friendly Abrasives | Plastic Media (PE/PP) | Low | Reusable | Low | Aerospace electronics, soft substrate coating removal |
Walnut Shell / Corn Cob | Low | Reusable | Low | Cultural relics, molds, eco-friendly cleaning |
The sandblasting media grit is the size of the abrasive particles, usually measured in mesh.
Mesh is the number of holes per square inch of screen. The larger the mesh is, the finer the particles is; the smaller the mesh is, the coarser the particles is.
For example: 80 mesh means particles pass through a screen with 80 holes per inch. 220 mesh are finer and need to pass through a denser screen.
Coarse Grit: 20~80 mesh (about 850~180 micron) – powerful rust removal and thick coating removal;
Medium Grit: 80~150 mesh (about 180~100 micron) – general cleaning and surface roughening. Medium Grit: 80~150 mesh (about 180~100 micron) – general cleaning and surface roughening;
Fine Grit: 150~400 mesh (about 100~20 micron) – fine polishing, matte finish;
Very Fine Grit: 400 mesh or more (<20 micron) –High-precision surface treatment (such as optical components).
Steel grit/steel shot: wide range of Grit (20-200 mesh), suitable for metal strengthening.
Glass beads: commonly used fine Grit (100-400 mesh), suitable for polishing and precision cleaning.
Alumina/Silicon Carbide: high hardness, wide Grit span (60-600 mesh), suitable for a variety of scenarios.
Walnut shell/corn cob: natural soft abrasive with coarse Grit (10-60 mesh), for environmental cleaning.
Coarse Grit (20-60 mesh): Ra 5-15 μm, obvious texture, suitable for heavy industry;
Medium Grit (80-150 mesh): Ra 2-5 μm, uniform roughness, enhanced coating adhesion;
Fine Grit (180-400 mesh): Ra 0.5-2 μm, smooth and matte, used for decorative or precision parts.
Depending on whether the liquid is used or not, sandblasting is classified into dry sandblasting and wet sandblasting.
Dry sandblasting directly uses compressed air as the driving force to blast dry abrasives onto the surface of the workpiece at high speed.
The advantages of the dry sandblasting are listed below.
High cleaning efficiency, suitable for removing stubborn rust or thick coatings;
Higher dust, need to be equipped with dust removal equipment;
Abrasives can be recycled and reused, but long-term use may produce dust pollution.
Typical applications of dry sandblasting include metal descaling, mold cleaning, surface roughening treatment, etc. Meta usually use dry sand blasting, focusing on rust prevention and strengthening.
Wet sandblasting mixes abrasives with water and then blasting or driving abrasives through high pressure water.
The advantages of wet sandblasting are listed below.
Less dust, better environmental protection;
Water can lubricate the surface, reduce the impact of abrasives on the workpiece damage;
May need to deal with wastewater, and abrasive recycling is more complex.
Typical applications of wet sandblasting are precision parts processing, glass/ceramic surface matte processing, dust-sensitive environments. Brittle materials like glass, ceramics, usually use wet blasting because of low pressure fine treatment.
According to the operation mode, sand blasting can also be divided into manual sand blasting and automatic sand blasting.
Manual sand blasting requires the operator to hold the spray gun and flexibly control the spray angle and position. It is suitable for small quantities, complex shapes or workpieces with high requirements for details.
Manual sand blasting is lower efficiency, high labor intensity and higher requirements for operator experience. The operator need to strictly wear protective equipment, like dust masks and gloves.
Automatic sand blasting relies on equipment programs to control the movement of the nozzle and spraying. It is suitable for large quantities, standardized workpieces, improving efficiency and consistency.
We visited many Chinese sandblasting factories. Most of them have both automatic and manual sandblasting machines to meet the varying needs of CNC parts, small or large batches, with a balance of efficiency and flexibility.
Sandblasting is applicable to a wide range of materials.
Steel and Iron can be sandblasted to remove rust, roughen surface to enhance coating adhesion, and improve fatigue resistance.
For high-carbon steel, blasting pressure must be controlled to avoid surface over-hardening. Stainless steel should be thoroughly cleaned after blasting to remove residual media and prevent localized corrosion.
Sandblasting can remove oxide film of aluminum and aluminum alloy, create matte finishing, and prepare for the anodizing and painting.
Avoid iron-based abrasives,e.g., steel grit, to prevent iron contamination and galvanic corrosion. Softer abrasives like glass beads or ceramic media are recommended.
Sandblasting can clean copper and copper alloys surface and remove oxidation layer, achieve decorative matte finishes.
Use sandblasting with low-pressure and non-metallic abrasives to avoid deep scratches and preserve surface luster.
Oxide layer is removal by sandblasting titanium.
Glass can be sandblasted to get frosted effects (decorative glass), coating removal, cleaning of precision instrument glass
Sandblasting glass shall use fine abrasives and low-pressure settings. Wet blasting helps reduce chipping risk.
Sandblasting can roughen ceramics surface roughening, remove residue, and get matte finishes. Avoid high-pressure blasting to prevent microcracks. Silicon carbide or aluminum oxide abrasives are recommended.
Sandblasting can clean the stone surface, antique and carve the relief.
Choose abrasives based on stone hardness and void over-blasting to prevent surface powdering.
Sandblasting can debur plastic and polymer, roughen the surface and get matte finishing.
Use low pressure and soft abrasives (e.g., plastic media, walnut shells). Avoid overheating, which can cause deformation.
Surface cleaning, resin layer removal, increased bonding strength. Use low-pressure sandblasting to prevent fiber damage.Recommended abrasives arealuminum oxide or glass beads.
Mold release agent removal, surface roughening. Control abrasive grit size to avoid fiber breakage.
Rubber can be sandblasted for tire retreading.Use very low pressure and ultra-soft abrasives like corn cob powder. Avoid excessive heat and prolonged blasting.
Wood can be sandblasted for antiquing, surface texture enhancement. Use natural abrasives (e.g., walnut shells, coconut shell powder) and control blasting depth to avoid damaging wood fibers.
Material Type | Recommended Abrasives | Typical Applications |
Metal (Steel, Aluminum) | Steel grit, Aluminum oxide, Glass beads | Rust removal, Strengthening, Surface roughening |
Glass/Ceramics | Glass beads, Silicon carbide | Matte finishing, Precision cleaning |
Plastic/Rubber | Plastic media, Walnut shells | Deburring, Surface activation |
Stone | Quartz sand, Garnet | Engraving, Cleaning |
Composite Materials | Aluminum oxide, Glass microspheres | Surface roughening, Resin layer removal |
Avoid sandblasting for the following materials.
Ultra-soft materials (e.g., silicone, foam): Easily penetrated or deformed by abrasive media.
Precision optical components (e.g., lenses): Extremely high surface accuracy requirements—blasting may cause scratches.
Uncured coatings: Blasting can damage the coating structure before it fully cures.
Sandblasting before anodizing aluminum is widely used, which almost become a standard process step—especially in consumer electronics and precision structural components.
Sandblasting aluminum removes tool marks, eliminating microscopic tool lines left from CNC machining (Ra should be controlled between 0.8–1.6 μm).
Sandblasting can also uniform roughening, creating a consistent micro-rough surface for anodizing.
Another advantage is to cleans off residual cutting fluid to prevent blotches after anodizing.
Glass bead is the abrasive that commonly used. #120 grit is a standard choice.
What is Sandblasting Aluminum?
Sandblasting is used to remove rust, scale, and welding slag for steel components such as structural parts, frames, and molds. This is a standard surface preparation step.
Sandblasting is an ideal surface preparation step before powder coating. It is widely used for sheet metal parts, large structural components, and mechanical enclosures, helping the powder adhere more securely to metal surfaces.
Grit size #60 to #80 is the most common grit in powder coating workshops.
For precision components like mechanical enclosures or display frames, #100 to #120 grit balances adhesion and appearance.
The cost of sand blasting is related with many factors, including labor costs, equipment depreciation, abrasive consumption, power and air costs, as well as the handling and cleaning of the workpiece.
Different sandblasting methods also have obvious differences in cost structure. Manual sandblasting is suitable for small batch or complex structure of workpieces, with manual operation mainly and lower efficiency.
Automatic sandblasting is suitable for mass production, with high efficiency and lower cost per piece.
Here are some piratical sandblasting cost for sandblasted aluminium parts. For a palm-sized aluminum part, the charge for manual sand blasting is usually between RMB 0.3 and RMB 1.5 per piece. The cost will increase for a large part or a complex structure accordingly.
With automated blasting, if the batch size is greater than 100 pieces, the cost of blasting a single piece can be controlled between 0.2 and 0.8 yuan.
Some China sandblasting factories may also charge based on weight.
What’s more, other factors affect sandblasting cost, for example like abrasive type, grit size, whether or not masked blasting is required, and the customer’s special requirements for surface uniformity.
Generally speaking, the finer the mesh size and the higher the precision required, the cost will rise slightly.
For high-end products such as consumer electronics housings, medical equipment appearance parts, etc., the uniformity and consistency of sand blasting is required to be higher, and the processing cost will be increased accordingly.
If the customer needs to cover the tooling marks in the aluminium CNC machined parts,it is recommended to use glass beads with 120 mesh. If the grit is too coarse, the surface may look rough. If the grit is too fine, the tooling marks may still be visible.
Powder coating requires high adhesion. Sandblasting abrasive with 60-100 mesh to ensure that the surface has enough roughness. Too fine grit will cause the powder to fall off, and too coarse will damage the workpiece.
Before sand blasting, the surface and holes the CNC workpiece must be thoroughly blown clean with compressed air to prevent dust, grease and other impurities.
Otherwise, the sandblasting abrasive will adhere to the oil, resulting in uneven surface or subsequent coating failure.
Sand blasting pressure and distance: adjust the sand blasting pressure and nozzle distance according to the material and size of the workpiece. Aluminum parts usually use 0.4-0.6MPa pressure, nozzle distance to maintain 15-30cm, to avoid local over blasting resulting in surface craters or deformation.
Sand blasting time and angle: too long sand blasting time will cause excessive wear and tear of the workpiece, the angle is controlled at 45~60 degrees best.
When manually sandblasting, the operator should move the nozzle evenly, avoiding larger roughness for overstaying too long.
Clean and inspect the workpiece after sand blasting, especially the holes and the inner wall of the threads, to avoid impurities affecting the subsequent process.
Use visual inspection and roughness meter to confirm whether the surface is up to customers’ requirement, and make comparison samples if necessary.
For powder coated parts, carry out a trial powder test to ensure that the adhesion and appearance are in line with customer requirements.
Communicate with customers to confirm sand blasting mesh and surface requirements, which vary greatly from customer to customer and from application to application.
Abrasive replacement cycle should be adjusted according to the batch and wear and tear in time, the aging of the abrasive will reduce the effectiveness of sandblasting and increase the rate of defective products.
The sandblasting site should keep clean and oil-free, otherwise the sandblasting effect will be greatly reduced.
Some high-precision CNC parts have high requirements for dimensional tolerances, and may require a second inspection to adjust the dimensions after sand blasting.
In CNC machining, sandblasting are important. The tooling marks may be visible after precision machining.
If sandblasting is not done properly, these imperfections not only affect the appearance but can also become more pronounced after anodizing, leading to uneven finishes and compromising the overall texture and performance of the product.
High-quality sandblasting effectively removes machining marks, enhances surface uniformity, and creates the ideal surface roughness for anodizing—ensuring a strong, consistent anodizing layer.
ECOREPRAP works closely with professional sandblasting and anodizing partners. They have extensive experience handling international orders and are well-versed in meeting high-end surface treatment standards.
These partners are capable of adjusting blasting media, grit size, and parameters flexibly to suit each customer’s specific needs—ensuring that every batch of parts meets world-class standards.
With consistent quality and efficient delivery, ECOREPRAP’s sandblasting and anodizing services help clients achieve high-value, premium surface finishes for CNC parts—earning widespread recognition from both the market and customers.
Sand blasting is a type of abrasive blasting. Their difference is the type of abrasive used.
Sand blasting (Sandblasting), refers to the use of sand, traditionally mostly quartz sand, as an abrasive, through the high-speed air jet to the surface of the workpiece, to clean up, remove corrosion, old paint, or surface roughening purposes.
Quartz sand in sandblasting will produce more dust, harmful to the human body, and were not used.
Abrasive blasting is refers to all the use of different abrasives, such as aluminum oxide, steel sand, glass beads, plastic sand, ceramic sand, etc.,for high-speed blasting process.
Abrasive blasting selects different materials and coarseness of abrasives to suit different surface preparation requirements, such as finer surface cleanup, more efficient rust removal, or gentler decorative effects.
In one word, sandblasting is a subset of abrasive blasting, and abrasive blasting covers a wider variety.
For historical reasons, sandblasting term is still used in some industries as a substitute for abrasive blasting.
Bead Blasting is another type of abrasive blasting, which use round glass beads as the abrasive.
Bead blasting has a gentle impact. It is suitable for even surfaces, removing machining marks and adding visual aesthetics to metal surfaces.
Glass beads do not cause significant material removal from the workpiece . Beadblasting process is suitable for CNC aluminum, titanium, and stainless steel parts that require high dimensional accuracy and avoid deforming.
Bleadblasting is used quite a lot for CNC machined aluminum parts before anodizing.
Difference between beadblasting and sandblasting also lies in the difference of abrasives.
Bead Blasting vs Sand Blasting
Shot peening is a metal surface peening process. The abrasive materials are steel, stainless steel or ceramic. The process shot abrasives onto the surface of the workpiece at a controlled speed and angle.
Shot peening produces small plastic deformations and residual compressive stresses. They can improve the fatigue strength, wear resistance and crack resistance of the metal part.
Sanblasting aims to clean or remove material,while shot peening can enhance the mechanical properties of parts.
A brief understanding of the difference between sandblasting and shot peening.:
Sandblasting = surface cleaning and pre-treatment;
Shot peening = material surface peening technique.
Lucas is a technical writer at ECOREPRAP. He has eight years of CNC programming and operating experience, including five-axis programming. He also spent three years in CNC engineering, quoting, design, and project management. Lucas holds an associate degree in mold design and has self-taught knowledge in materials science. He’s a lifelong learner who loves sharing his expertise.
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