Should I get an orbital or hand sander?

When it comes to sanding wood or metal, choosing the right sander for the job is important. The two main types of sanders are orbital sanders and hand sanders. Both have advantages and disadvantages depending on the specifics of the sanding project. This article will compare orbital and hand sanders to help you decide which is best for your needs.

What is an orbital sander?

An orbital sander, also known as a random orbital sander, uses sandpaper that is attached to a round pad that spins in random orbital motions. This allows the sander to smooth materials without leaving scratches or sanding marks. Orbital sanders are powered by electricity and feature variable speed settings to match the needs of different projects.

Some key features of orbital sanders include:

• Pad sizes ranging from 3 inches to 6 inches or more
• Dust collection systems to contain sanding debris
• Ability to use various grits of sandpaper
• Electric power for continuous sanding
• Variable speed settings from around 8,000 to 12,000 RPM

Orbital sanders are a good choice for sanding large, flat surfaces like tabletops, boards, cabinets, and decks. The random orbital motion helps provide an even, consistent sand on these types of projects. Many orbital sanders also allow you to attach a vacuum to collect dust while working.

What are the benefits of an orbital sander?

Some of the key benefits of using an orbital sander include:

• Smoothing large surfaces – The circular sanding motion covers a wide area evenly and efficiently.
• No sanding marks – The random orbit pattern eliminates unsightly scratches and swirl marks.
• Quick sanding – Electrical power allows fast stock removal and smoothing compared to hand sanding.
• Consistent results – A uniform finish across the workpiece without uneven sanding.
• Can use for finer grits – Good for final smoothing stages with fine 120+ grit sandpaper.
• Dust collection – Many models can attach to a shop vac to reduce dust inhalation.

Orbital sanders are a versatile choice for all types of sanding from initial smoothing to final finish sanding. The random action helps blend imperfections for a consistent surface.

What are the drawbacks of an orbital sander?

The disadvantages of orbital sanders include:

• Size limitations – Not ideal for sanding confined areas or small workpieces.
• Learning curve – Takes practice to master consistent pressure and direction.
• Potential swirl marks – Minor swirls can still occur if not used properly.
• Electricity required – Corded models limit mobility and battery models have limited runtime.
• Dust production – Even with dust collection attached, fine dust is still produced.
• Higher cost – Quality orbital sanders typically cost $100 or more.

While orbital sanders are very versatile, they aren’t the best choice for detailed sanding in corners or on narrow pieces. Novices may also struggle with controlling sanding pressure initially. Overall, orbital sanders excel at wide surface smoothing but have some limitations in agility and dust production.

What is a hand sander?

Hand sanders, also called sheet sanders or palm sanders, utilize a flat sanding pad under a rectangular sandpaper sheet. The user provides the sanding motion manually, usually in a back-and-forth direction. Hand sanding blocks are also a form of hand sander.

Key attributes of hand sanders include:

• Lightweight and compact size
• Various palm grip designs
• Use common, replaceable sandpaper sheets
• May have dust extraction holes
• Provide user control of sanding speed and pressure
• Typically cost $20 or less

Hand sanders are ideal for sanding contoured workpieces, confined spaces, edges, and detail areas. The small size allows access to spots that are hard to reach with a large orbital sander. Hand sanding also gives the user more precision and control over the sanding path and pressure.

What are the advantages of a hand sander?

Benefits of choosing a hand sander contain:

• Maneuverability – Easy to grip and sand hard-to-reach areas.
• Affordability – Basic hand sanders are inexpensive to purchase.
• Detail sanding – Precision control for detailed edges and curves.
• User control – Pressure and speed vary based on need.
• No power source – Completely portable for any location.
• Small footprint – Takes up little space in a toolbox or cabinet.

Hand sanders allow dexterous sanding of confined spaces. They also provide flexibility in sanding direction, speed, and pressure. With practice, a uniform finish is possible without bulky power tools. Hand sanders are highly affordable and mobile as well.

What are the disadvantages of a hand sander?

Potential downsides of hand sanders include:

• Slow stock removal – Manual labor limits speed and area covered.
• Hard to sand large areas – Not practical for big, open surfaces.
• Fatiguing – Hand sanding can tire out the arm muscles.
• Less uniform result – Finish quality depends on user skill.
• Dust exposure – No dust collection without a vacuum attachment.
• Requires frequent sandpaper changes – Sheets wear out faster than machine discs.

Removing a lot of material by hand takes patience and effort. Covering large flat surfaces is also time consuming without a power tool. Novices may end up with an uneven finish as their skill develops. Hand sanding does create significant dust too. Overall, hand sanders are best for small-scale jobs rather than industrial workshops.

How do you decide between an orbital or hand sander?

Choosing between an orbital or hand sander depends on several factors:

Project Type

Orbital sanders excel on broad, open surfaces like tabletops, doors, cabinets, and decks. A hand sander is better for sanding detailed moldings, curved legs, corners, and confined areas.

Amount of Material Removal

An orbital sander will remove stock much quicker than by hand. If you have thick surfaces to smooth down, orbital is the way to go.

Project Size

A hand sander is only practical for smaller projects or tight spots on larger projects. Orbital sanders have the advantage on overall surface area.

Power Source

Hand sanders are completely portable with no cords. Orbital sanders limit mobility somewhat and battery runtime is finite.

Dust Control

Orbital sanders can attach to dust collection systems fairly easily. Hand sanders require more effort to reduce airborne dust while working.

Precision Needed

The free range of motion of hand sanders allows more control for detailed curves and edges. Orbital sanders excel at uniform flat sanding.

Budget

Hand sanders are very inexpensive at around $20 or less. Orbital sanders start around $100 for decent consumer models.

Skill Level

Beginners may find hand sanders easier to learn on before graduating to orbital sanders. Professionals can achieve great results with both sander types.

What are the key specifications to compare?

When choosing between different models of orbital or hand sanders, there are some important specifications to consider:

Orbital Sanders

• Disc size – Standard sizes range from 3 inches up to 6 inches or more. The right size depends on your typical project.
• Speed – Measure in rotations per minute (RPM). Variable speed is preferred to match different grit sandpapers.
• Pad style – Some use hook-and-loop for easy paper changes while others have clamping systems.
• Dust collection – Look for models with ports to attach vacuum hoses.
• Cordless or corded – Battery operation provides maximum mobility.
• Warranty – Can indicate quality and longevity of electric motors.

Hand Sanders

• Size – Needs to fit comfortably in your hand for extended use.
• Grip shape – Contoured grips reduce hand fatigue vs flat styles.
• Backing pad – Foam pads smooth out imperfections better than hard plastic.
• Dust extraction – Some have holes to attach vacuum hoses for dust reduction.
• Single or dual grit – Dual grit models have pads for coarse and fine sanding.
• Added features – Look for extras like fingertip controls and secured sandpaper clamps.

What is the sanding process using each sander type?

Both sanders follow the same basic sanding sequence but the steps vary somewhat between models:

Orbital Sander Process

1. Select the appropriate grit sandpaper for the current sanding stage.
2. Attach the sandpaper to the sander backing pad securely.
3. Connect shop vacuum hose if available.
4. Plug in sander and adjust speed as needed.
5. Position sander on workpiece, apply light pressure, and move steadily across grain.
6. Overlap passes to ensure an even result.
7. Progress through finer grits until desired smoothness is reached.
8. Detach and clean sander when finished.

Hand Sander Process

1. Choose correct grit sandpaper for current stage.
2. Cut sandpaper to size of sander backing pad.
3. Attach sandpaper firmly to backing pad.
4. Optionally connect vacuum hose if model allows dust extraction.
5. Grip sander securely and begin sanding using smooth strokes following the wood grain.
6. Overlap passes while adjusting pressure as needed.
7. Continue transitioning to finer grits per project needs.
8. Remove sandpaper and clean sander when completed.

While the orbital sander uses power assistance, both processes follow similar sanding fundamentals. Proper grit progression and technique leads to the best results.

What are common sandpaper grits to use with each sander?

The ideal sandpaper grit depends on the current stage of the project, but some typical grits include:

Orbital Sander Grits

• 60-80 grit – Aggressive removal of material and imperfections
• 100-120 grit – Smoothing out marks from coarser sanding
• 150-180 grit – Fine tuning smoother surfaces
• 220+ grit – Final finish sanding before painting/staining

Hand Sander Grits

• 80-100 grit – Quickly smoothing imperfections
• 120-150 grit – Blending and refining surfaces
• 180-220 grit – Prepping for finish coats
• Higher grits for polishing

Orbital sanders are well suited to more aggressive grits for bulk removal. Hand sanders typically start finer and focus on detail blending and refining.

What safety tips should you follow?

Proper safety precautions are important when using power tools like orbital sanders as well as hand tools:

• Wear eye protection to block airborne dust and debris.
• Use a dust mask or respirator to avoid inhaling fine particles.
• Wear hearing protection when using loud orbital sanders.
• Prevent electrical hazards by keeping cords away from water.
• Follow all manufacturer safety guidelines provided with tools.
• Unplug orbital sanders before changing discs or performing maintenance.
• Keep proper footing and don’t overextend your reach.
• Allow motors to cool before changing sandpaper or putting away.

Taking basic safety steps goes a long way to prevent injuries and keep tools performing their best. Consult tool manuals for further device-specific safety information.

Conclusion

Orbital and hand sanders both have distinct advantages depending on the specifics of a sanding project. Orbital sanders excel at efficiently smoothing large flat surfaces. Their random orbital action creates a uniform finish without sanding marks. Hand sanders provide affordable flexibility for confined spaces, details, edges, and user control. While hand sanding takes more effort and time, it allows access to spots orbital sanders can’t reach.

Consider factors like project size, precision needed, power source, and budget when deciding between the two. Proper sanding technique and safety precautions are also key to success. With practice, both orbital and hand sanders can produce professional quality results. Evaluate each project’s unique requirements and choose the sander that best fits the job.