Air vs Electric Sander

[Michael Sloop]

I have historically used an electric orbital and palm sander. I recently got a 60 gallon, 3.7 Hp compressor. I'm wondering if I should start using air sanders, but I don't know what the difference is, if any, in an electric vs air sander. Thanks in advance for your help.

[Jim Becker]

Seemingly, an air sander should be less complicated and potentially have longer life. But there are also challenges with things like required SCFM to power it (be very careful about that before you spend the money...your compressor actually may not be enough for some of the air sanders) and dust collection isn't always a feature, despite being a "requirement". You also want to be sure it's a "random orbit" mechanism and not just rotary for woodworking purposes. Air sanders really shine in production environments because of the longevity I mentioned earlier. They are less typical for smaller shops, as far as I've noted. It would be very hard to convince me to move to air sanders from my Festool sanders, quite honestly.

[Martin Wasner]

How many cfm at what pressure is your compressor? I've got an 80 gal two stage compressor that is 5hp, it can keep up with a Dynabrade, but it's running hard.

Before getting a Mirka Ceros I swore by the Dynabrade, now not so much. But Jim is correct, they are more or less indestructible. I've got a couple of them going on ten years. I'll be happy to get more than a couple of years out of the Mirka's.

[Myk Rian]

My air sander takes stuff off in a hurry. I like it better than electric, BUT, it does use a lot of air. Just like my needle scalers.
60 gal with 3.5hp ought to power it fine. Might have to take a break now and then.

[Michael Sloop]

The compressor produces 11.5 cfm at 90 psi.

[David Kumm]

That is on the low end for a Dynabrade. 15 cfm is better. The compressor will run hard, air will not sit in tank long so will come out warm and need a dryer or you will spit water in humid times. I really like the air sanders but you do need a true 5 hp 15-17 cfm compressor. Dave

[Rick Johnston]

X2 what Myk said.

[Art Mann]

The way I use a random orbital sander woodworking, dealing with a compressed air hose would provide an incredible nuisance. The one that is right for you is dependent upon what you are doing with it. An air sander is ideal for sanding down car paint, for example. I use both at different times.

[Martin Wasner]

Art, you need to try different hoses. The poly ones weigh nothing and are very flexible.

[Ole Anderson]

Seems awfully inefficient, using a 5 hp compressor to do what a 5 amp electric sander can do almost as well.

[Tom Ewell]

I use the air when I wet sand (not wood) I use the Ceros or Festools with dust extraction on wood and wood finishes. All of the hoses are a pain for sure but being virtually dustless sanding using either method makes for a much more enjoyable endeavor.

[Martin Wasner]

Seems awfully inefficient, using a 5 hp compressor to do what a 5 amp electric sander can do almost as well.


That's the main reason I switched over to the Mirka sanders. I'm looking at a 15hp screw type compressor with the line dryer and filter built in. (Originally I was looking for a 25hp, but I was looking at the wrong stuff) I'm hoping to add a cnc in the next couple of years and it needs almost 16cfm on its own. Nevermind everything else in the shop gobbling up air. Compressors are exponentially expensive. If 10 cfm costs say $100, 20 cfm costs $300. Even if the Mirka's don't last as long as a dynabrade, (which they will not), the savings in a zillion watts getting burned up by an extremely expensive air compressor makes up for the lack of longevity with the electric sander.

[peter gagliardi]

I'm sure you already know Martin, but ideally if you get a rotary screw, it would be VFD driven to respond to air demand, apparently the electric savings are significant.
I was never happier than the day I put the air sander on the shelf. The electrics with vacs are soooooooooo much more versatile and portable!

[Martin Wasner]

I'm sure you already know Martin, but ideally if you get a rotary screw, it would be VFD driven to respond to air demand, apparently the electric savings are significant.
I was never happier than the day I put the air sander on the shelf. The electrics with vacs are soooooooooo much more versatile and portable!


I have a buddy of mine who is a mechanical engineer that does energy audits tell me that a few years ago when I first started thinking about getting a big angry compressor. I asked a salesman about it and he said on a small scale it doesn't pay. You have to get in to the 50+ horsepower range before the initial cost will be out weighed by efficiency savings. That has likely changed though considering how inexpensive that stuff has become, and I should probably inquire about it again.

[peter gagliardi]

We have/had an incentive program from the power company about 10 years ago, and qualified for a rebate, and bought a 7.5 hp rotary on a 80 gal tank. Was around $7-8k as i remember, and they were paying about $2500-3000 of that i think.
We had it for a short time.
I was really,really impressed with the quietness of it.
I think that particular unit didnt play well with our antiquated power supply in the building we were renting and we had some issues.
We got nervous, and sent it back.
I wish we hadn't!

[Martin Wasner]

I hadn't thought about looking to see if there was any incentives through the power company. Good call.

I'd should look and see what else is available, lighting, boiler, etc, too since the new building is going up soon. I hate it when I don't think of this stuff myself

[David C. Roseman]

Martin, perhaps not an issue for your situation, but one thing not mentioned in this thread is the noise factor at the tool. My straight-line and orbital air sanders have the high-pitched scream that I associate with most hand-held air-driven tools. They are not high-quality, so maybe that's part of the problem. But my electric sanders are much quieter. Just something else to consider.

[Martin Wasner]

Martin, perhaps not an issue for your situation, but one thing not mentioned in this thread is the noise factor at the tool. My straight-line and orbital air sanders have the high-pitched scream that I associate with most hand-held air-driven tools. They are not high-quality, so maybe that's part of the problem. But my electric sanders are much quieter. Just something else to consider.

Other than a orbital, the only other thing that I've really had much exposure to is drills. The drills are wicked loud, and high pitched. The Dynabrades are loud as well, but much lower tone and a lot less painful to listen to for long periods. Castle makes a pocket screw machine that one of the routers runs on air. We need to get a second one sometime in the future and I've been considering their heavy duty model. I've never used one, and only seen one in factory setup, I have to image its seriously loud and gobbles a lot of air though. It's also twice the money compared to the model I currently have and most cabinet shops run around here.

I'm pretty sold on the Mirka's at this point. It's a very cost effective way to sand, and you are correct, much quieter compared to an air powered one.

[jack duren]

Other than a orbital, the only other thing that I've really had much exposure to is drills. The drills are wicked loud, and high pitched. The Dynabrades are loud as well, but much lower tone and a lot less painful to listen to for long periods. Castle makes a pocket screw machine that one of the routers runs on air. We need to get a second one sometime in the future and I've been considering their heavy duty model. I've never used one, and only seen one in factory setup, I have to image its seriously loud and gobbles a lot of air though. It's also twice the money compared to the model I currently have and most cabinet shops run around here.

I'm pretty sold on the Mirka's at this point. It's a very cost effective way to sand, and you are correct, much quieter compared to an air powered one.

I'm not sure what drills you use but I use several SIOUX drills and there not loud and neither are the Dynabrades. Now we are big enough that Mirka, Dynabrade and Senco bring us these products for free hoping to get our business...