Sign Sand Blasting Process
Sandblasted signs contain flexible and thick masking materials that adhere to the wood, protecting it from erosion throughout the sandblasting process. There are many different steps involved in creating sandblasting sands. Once the layout and design process have been completed, the fabrication begins.
First Step: Constructing the Blank Sign
The basic shape of the sign before the sandblasting process is known as a “Sign Blank”. Sandblasted wood signs are usually made from clear grade lumber, which is fairly thick and easy to work with. The lumber is treated under extreme conditions to keep it from cracking or warping. Only select boards will make it through this harsh process.
Some signs are created from a high density, open celled urethane foam called HDU. HDU foam is extremely versatile, making it a good choice when creating signs with unique shapes. For projects that require a wooden-style texture, a simulated wood grain is added to create a realistic effect. Many finishes and textures can be produced using HDU foam.
Second Step: Masking the Blank Sign
A sandblasted sign has a dimensional effect that is made by blasting the blank sign while covering it with a rubber mask. The rubber mask is cut from a digital design and is placed on the sign prior to sandblasting. The areas of the sign that will be sandblasted are cut out of the mask. This mask raises the protective areas and gives the surface a dimensional appearance.
Third Step: The Sandblasting Process
Sandblasting is a form of art. Dry, cool air is assembled in a sand tank at an extremely high pressure. The sand and air mixture is then channeled through a nozzle, stripping at everything it meets. The rubber mask will protect the certain parts by blocking the blasting mixture, causing it to simply bounce off. However, the exposed areas are eroded away, creating beautiful patterns in the wood or foam surface. After the sandblasting is finished, the sign thoroughly cleaned out to get rid of any sand particles left. Next, it is prepared for the finishing and priming process.
Sandblasting can be very dangerous because the sand is thrown at extremely high pressure and can easily destroy human skin. While this process is in effect, individuals should be in another room protected either by steel or very thick glass. Once the process is over, the room will need some time to settle down before the air is safe enough to breath. Safety glasses should always be worn when working with sandblasting.
Fourth Step: Priming the Sign
Blasted signs are primed according to their theme and use. All signs have different finishing requirements unless they are being mass-produced. To ensure long-life, your sign should be treated with materials that will protect it from rain, sun, and dirt. Raw sand blasted signs are very rough and may require several coats of primer in order to get a proper seal. A simpler solution is to apply the priming layer using a pressurized sprayer, although this can be a messy and expensive method for only treating one or two signs.
Each primer layers should be applied in a very thin coat and then left to dry. Once the primer has dried, lightly sand down the surface and add another coats. Multiple coats help create a strong barrier of protection against weather elements. However, not all signs need to be primed. Some natural wood materials are rich and beautiful in detail and do not require a protective layer. Nevertheless, your sign should have a priming layer if it is outdoors.
Fifth Step: The Finishing Touch
A variety of stains and clear coats can be used to decorate the sign after it has been shaped. You should use good quality materials to ensure that the colors will remain for a long time. A properly treated and maintained sign can last for decades if it is kept in the right conditions.
Making Your Own Sand Blasted Sign
Sandblasting a sign yourself is a very difficult process, but not unheard of. The biggest obstacle is obtaining a sand compressor as it is very expensive to purchase or even rent. A safe environment and proper tools are also required to ensure the safety of the individual working on the project. Overall, trying to sandblast the sign yourself is complicated and dangerous without proper equipment and experience.
However, you can have your own custom sign sandblasted by contacting a company that specializes in unique signs. Many of them will allow you to create your own design and then submit it to the company so they can sandblast it for you. This method cost far more than making your own sign, but companies who want their logo on their sign will need to use this process in order to create a unique trademark.