Sandblasting 101: Choosing the Right Tip, Pressure, and Media for the Job

Sandblasting results come down to three variables you control: feed type, tip size, and pressure. Get those matched to the job — etching glass, stripping rust, or prepping metal for paint — and even an entry-level gun kit will produce clean, consistent results.

Siphon Feed vs. Gravity/Dual Feed

Siphon-feed guns pull media from a separate container using the vacuum created by the airstream — simple and portable, but pressure drops off if the media container is far from the gun. Dual-feed and gravity-feed guns, which use a hopper mounted directly on the gun, deliver more consistent media flow and are the better choice for anything beyond light, occasional use.

Ceramic Tip Sizes

Tip diameter controls how concentrated the blast pattern is. Smaller tips (around 1/8") concentrate media into a tighter stream — good for detail work like etching or cleaning small parts. Larger tips spread the pattern for faster coverage on bigger surfaces like a rusted panel or frame section, at the cost of precision. Ceramic tips resist the wear that media causes far longer than brass or aluminum tips, which matters if you're doing more than an occasional small job.

PSI by Task

• Glass or delicate etching: 40-60 PSI — enough to frost the surface without cracking it.
• Light rust or surface prep: 60-90 PSI.
• Heavy rust or old paint removal: 90-125 PSI, with a larger tip to cover ground faster.

Start at the low end of a range and step up only if the media isn't cutting fast enough — it's easier to add pressure than to undo damage from starting too aggressive.

Media Matters as Much as Pressure

Fine media like glass beads or baking soda is suited to etching and delicate surfaces. Coarser media like aluminum oxide or crushed glass cuts faster through rust and paint but leaves a rougher surface profile — which is actually desirable if you're prepping metal for a new coat of paint, since it gives the primer something to grip.

A Safety Note

Always blast in a contained, ventilated area, wear a respirator rated for the media you're using, and keep the nozzle moving — holding it in one spot at high PSI on thin metal will cut through it.

Frequently Asked Questions

Which is better for a home garage, siphon feed or dual feed?

For occasional, light use, siphon feed's simplicity and portability work fine. If you're doing more frequent or heavier jobs, a dual-feed or gravity-feed gun delivers more consistent media flow and is worth the extra cost.

Why choose a ceramic tip over brass or aluminum?

Ceramic resists the abrasive wear that media causes far longer than brass or aluminum, which matters once you move beyond occasional small jobs — a worn tip loses its concentrated blast pattern and becomes less efficient.

Is it better to start with too little pressure or too much?

Always start too little. It's easy to step up pressure if the media isn't cutting fast enough, but starting too aggressive risks damaging the surface — especially thin metal or delicate materials like glass — before you realize it's too much.

Why does a rougher surface profile help before painting?

A rougher profile from coarser media gives primer and paint more surface area to grip onto, improving adhesion. That's why coarser media is often preferred for paint prep even though it leaves a less refined finish than fine media.

A dual-feed sandblaster gun kit with a ceramic tip and 18oz hopper covers most rust removal and prep work, and a portable handheld sandblaster is a better fit for smaller etching and detail jobs.