Most woodworking projects require sanding wood, so it’s not surprising why orbital and belt sanders are highly sought-after. However, more than getting a smooth surface, have you ever wondered which one is the better fit for your project?
In this Orbital Sander vs. Belt Sander review, I’ll break down the features and advantages of these power tools to see which one makes the sanding process easier.
Belt Sander Overview
Design-wise, belt sanders are bigger than other models. This size often translates into more power, making them formidable tools for sanding tasks.
Typically, you’ll find two variations of power belt sanders in the market: the stationary and handheld model. Nevertheless, both belt sander variations move in a looping motion that smoothens the material’s top wood grain.
Most belt sanders are also great at removing material in large strips, so this powerful tool is my go-to for tough and larger surfaces. It’s also the reason why they’re called finishing sanders.
How a Belt Sander Works
The sanding belt operates with an electric motor engine that powers two drums to move. These drum components run in a loop motion, allowing the sanding pad to smoothen the rough surfaces of the material in question. Here’s how the two variations of belt sanders differ.
Stationary Belt Sander
True to their name, these wood sanders are best used on a workbench while in a stationary position. It’s crucial to make sure this type of belt sander is firmly anchored; otherwise, it can move around unpredictably.
Large and flat surfaces may require buying bigger stationary belt sanders with a stand, but benchtop models are sufficient for regular tasks.
I should note that working with smaller pieces of wood is often easier, especially if you’re relatively new to woodworking. Handling wider boards can be a bit trickier.
You must get the wood ready and push it against the rotating sanding belt to get the desired sanding result. Unlike in other tools where the sander moves, the operator must navigate how the material will feed into the sanding machine.
Handheld Belt Sander
Although a handheld belt sander works the same way as the stationary model, it’s the power tool I prefer when working on large surfaces. Instead of moving the material into the belt sand, you can just put the board down and move the sander over it.
It’s also lighter than a stationary belt sander, giving users more portability and control during the sanding operations.
The Key Features of Belt Sanders
Speed
When I’m shopping for a belt sander, one of the key factors I look at is the speed, typically measured in feet per minute. If you’re keen on fast-paced work in your woodworking shop, getting belt sanders with higher speed specifications is the solution.
The operator’s skill level is often the biggest hurdle when using high-speed belt sanders. Like other powered machines in the industry, it’s crucial to consider cutting speed to avoid safety hazards [1].
Like any powerful tool, considering the cutting speed is essential to ensure safety in the workshop. That’s why I often prefer models with variable speed options. This feature allows me to adjust the belt sander’s speed to match the specific requirements of my project and achieve the desired results.
Sandpaper
In my experience, most belt sander sandpaper is commonly 3 inches wide. However, you can also find sanding pads that are thinner than 3 inches suitable for mini belt sanders.
Dust
When getting rid of dust in the workshop, most belt sander options feature two solutions; a vacuum system port or a dust collection bag. For the prior mentioned, you’ll have to connect an actual vacuum cleaner to suck the dust away.
Meanwhile, some models have a passive dust collection system. This function will suck sawdust inside the dust bag automatically and keep the workshop clean while the belt sander does its job.
(If you want to purchase a separate cleaning tool for your workshop, check this list of small shop dust collections, with a buying guide.)
Varieties
As mentioned earlier, you can choose between handheld and stationary models. However, it’s important to note that belt sander tools don’t have wide varieties as other sanders because they’re mostly focused on power.
Power
When considering belt sanders, I always pay close attention to their power capabilities. These tools are known for their heavy-duty sanding capacity, thanks to their substantial power amperage. You’ll typically find belt sanders with power specifications ranging from 8 to 11 amps.
Recommended Use
Using a belt sander is the ideal way to sand hardwood flooring. And because it’s a powerful and aggressive tool, it’s also more suitable for large furniture prices than smaller ones.
The Advantages of a Belt Sander
Quick Removal of Rough Wood Over a Wide Area
Given its size and design, you can rely on a belt sander to remove paint or smoothen rough surfaces on a wide area.
User-Friendly
This sander type isn’t complicated to use at all. You won’t encounter extra adjustments or complex assembly when using this tool because all you need to do is load the sandpaper, turn on the machine, and get the job done.
Durability
As these sanders offer more power, it’s no secret that they’re well-built for rough sanding conditions. The abrasive belts used in these sanders are also built to be highly durable.
It has a strong backing materials and high-quality abrasive particles that can withstand repeated use and resist wear and tear.
The Disadvantages of a Belt Sander
Not the Best for Fine Sanding
The thing about belt sanders is that while they pack quite a punch in terms of power, they’re not the best choice for fine sanding work. I’ve found that they can leave marks on the material, especially on wood pieces with intricate details, which can be a real downside.
Too Loud
Besides sanding marks, this sander can be loud during usage. If you don’t want to experience hearing damage, it’s a good idea to use ear protection.
Orbital Sander Overview
Instead of a belt, an orbital sander carries discs and sheets. It’s a handheld tool that moves in a circular pattern to produce smoother surfaces. Because of this, an orbital sander is likely to leave swirl marks on your material.
Compared to other alternatives, these machines are handy and portable. However, orbital sanders are not the easiest tool to handle.
How an Orbital Sander Works
Let me explain how an orbital sander works. It’s important to note that orbital sanders come in two main variations. First, you have the random orbital sanders that spin the sand pads in an inconsistent pattern.
And then, there’s also the sheet sanders. Unlike random orbital sanders, these tools include pads that only run in the same orbits.
The good thing about using a random orbital sander is it doesn’t leave marks. Considering how it doesn’t stay in one orbiting pattern, you don’t need to be mindful of its movement during usage. But if orbital sanders slow down while in use, there might be an underlying issue.
The Key Features of Orbital Sanders
Speed
Regular and random orbital sander options have speed specifications measured through orbits per minute or OPM. It indicates the number of times a random orbital sander will rotate within a minute.
Typically, regular orbital sanders with at least 10000 OPM should suffice. It’s also a common speed range for these tools, but getting a model with variable output is highly preferable for more user control.
Power
While orbital sanders offer enough power to handle typical sanding tasks like rounding edges, I don’t recommend it for tough materials.
You can initially use belt sanders for the rough part and switch to orbital sanders when you need to sand intricate corners or areas.
Handle Varieties
Palm Grip Handles
Some orbital sanders provide design handles that firmly fit your hand and are mostly equipped in smaller models.
Jug-Grip Handles
An orbital sander with a grip design is also called a D-handle, mainly because you can hold the tool on the back part instead of the top.
Pistol-Grip Handles
If you fancy the convenience of one-hand operations, then orbital sanders with pistol grip handles should fulfill your needs.
Accurate Work
Since they operate on repeated round angles, orbital sanders deliver more accurate results than alternatives. It’s also lighter and easier to wield, so it’s only natural that it’s easier to focus on precision when using it.
Recommended Use
If you’re working on projects that involve tight corners and rounding edges, smaller and more detailed orbital sanders are your best bet.
The Advantages of an Orbital Sander
The Sanding Disc and Sandpaper
It’s no hassle attaching sandpaper on an orbital sander because it only requires using velcro or stick-and-peel, depending on the model you purchase. Plus, sandpapers are readily available and cost-effective, which adds to the overall convenience of using this tool in my woodworking projects.
The Size and Shape
Most materials come in square or rectangular form, so it works well with the orbital sander’s tool shape. Its size also gives users more ease in reaching tight corners and edges.
The Smoothness
You can move an orbital sander back and forth, giving the material a smooth finish without the risk of sanding marks.
The Disadvantages of an Orbital Sander
Time Consuming
An orbital sander doesn’t offer massive power. Because of this, its speed isn’t up to par with more powerful sanding alternatives.
Restraints on Removing Materials
It’s not a tool meant for material removal or ripping, so there’s an obvious limit to how much an orbital sander can sand down.
Twisting Marks
As mentioned, an orbital sander works in a circular motion that causes twisted marks on the material.
What’s a Random Orbital Sander? How Does it Differ From an Orbital Sander?
Random orbital sanders also operate with circular movements. However, their orbits are more abrasive and less consistent. Here’s where you can best use these tools:
- Stripping wood pieces and fine sanding work
- Sanding work with no twisted marks
- Removing more material than regular orbital sanders
- More suitable for different wood projects
Also Read: SandNet vs Sandpaper
Belt and Orbital Sander In-Depth Comparison
Power
In this belt sander vs. orbital sander comparison, it’s clear that the orbital sander is better suited for finishing touches, and it doesn’t demand the same level of power as the belt sander.
Meanwhile, belt sanders are meant to be powerful to sand off more layers of the material. Overall, it depends on the sanding task you’re accomplishing.
Sanding Functionality
The looping motion belt sanders move with can get the material sanded off quicker than using an alternative. It’s a more convenient option than orbital sanders that use sanding papers to move in circles.
Sanding Grit
Although both tools can accommodate the available sandpapers in the market, an orbital sander can cater to almost every grit specification. On the other hand, belt sanders require specific sandpaper sizes.
Speed
As these tools are measured in different speed metrics, it can be hard to compare them. However, considering their power range, it’s apparent that belt sanders have an edge in the speed category.
Precision
If it’s precision on small sanding details, I’d recommend opting for a more handy and lighter tool like orbital sanders.
Uses
In this belt sander vs. orbital sander evaluation, I’ve already detailed the differences between these tools. Let me break down their specific purposes to drive the point home.
Here’s how you can use orbital sanders:
- To sand smaller areas and tight angles.
- For rounding and shaping the edge.
- For intricate workpieces.
Meanwhile, belt sanders are great when working on:
- Wooden hardwood floors.
- Wide and flat wooden boards.
- Highly rigid material surfaces.
Dust Collection
Although these tools differ in design and features, they have one thing in common: dust collection functions. Ultimately, it depends on the model you’re buying if it’ll have dust bags or vacuum ports.
Choosing the Right Sander for Your Needs
To reiterate, the sander you need depends on the project you’re working on. The more powerful belt sander is the best solution if you are engaged in large sanding tasks, including massive material removal.
However, if you need to sand down small workpieces or details, you should use the handy option, orbital sanders.
Also Read: Mortising vs Straight Router Bits
Conclusion
You don’t need to choose between the belt and orbital sanders, as these tools are crucial in any workshop engaged in frequent woodworking.
Although investing in both machines can be expensive, I believe they’ll be handy in the long run. After all, woodworking does not end in a single project or process.
You've probably seen his down-to-earth wisdom in USA Today, Bobvila, Family Handyman, and The Spruce, where he has shared commentary and guidance on various woodworking topics.
Robert is the brain behind Sawinery, where he aims to share tips, tricks, and a passion for all things carpentry.
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