How to Sandblast Signs

Select and Prepare Material and Design

• 1

  Select the type of material to be used for the sign, cut it to size and prepare it for sandblasting. Wood, wood substitutes (such as high density urethane), stone and glass are popular choices. Pick pieces that are thick enough not to warp after sandblasting, especially if sandblasting both sides. Plane and sand wood surfaces smooth and coat with a sanding sealer. Have stone surfaces and facings polished smooth where signage will be blasted.

• 2

  Layout your sign using your favorite graphics software. Print it out to size on a large format printer. Alternatively you may draw your layout by hand with pencil on large format layout paper. Sandblasting can produce great detail but take care not to make the design so fine that the carved surface material will break off easily.

• 3

  Affix a piece of frisket or rubber-masking resist material to the surface of the sign to be sandblasted. Your choice will depend on the material you are using and how deep you will be sandblasting it. Most friskets and masking material comes with a self-adhesive backing but use a removable spray adhesive if needed.

• 4

  Protect any exposed edges or other areas not covered by the masking material with heavy tape such as duct tape.

Transfer Design and Cut Resist Material

• 5

  Spray the back of your design printout or handmade layout with adhesive and position it on top of the frisket or masking material. Burnish it firmly to the surface with a linoleum block roller or similar tool.

• 6

  Cut through the design and completely through the frisket or masking material at the same time with a sharp craft knife held at a slight (60 degree) inward angle. Peel away the areas of the design that will be exposed to the sandblast abrasive. Burnish the edges of the remaining design to make sure your design is still firmly attached to the sign material.

• 7

  Use a specialty glass or sign shop with the capability to plot and cut frisket and masking materials from your digital files if you do not want to cut them by hand. Position and peel away the areas to be sandblasted the same way.

Sandblast and Finish the Sign

• 8

  Sandblast through the frisket or masking material with the sandblast head held at a right angle to the surface and about 10 inches away. Use the abrasive material and air pressure most suitable for the material you are using: 30- to 60-grit and 80-85 psi for wood, 45 psi for wood substitutes and 150- to 200-grit for glass. Do not sandblast more material than necessary for the desired carved effect.

• 9

  Remove the frisket or masking material to reveal the carved design.

• 10

  Relieve any extremely sharp edges of the design carved in wood or wood substitute with fine-grit sandpaper or steel wool.