There are basically two types of substrate used when sandblasting or routing signs: Wood and HDU. Price-wise, they are about the same. Wood tends to be stronger and more durable. HDU (high density urethane) is a foam product, so it's lighter (a plus for installation) but can also be damaged easily and is subject to pitting from environmental pollution. We prefer cedar wood, but have used quite a bit of Douglas fir and some oak. Cedar is the preferred wood for sandblasting because of ease of work, a natural bug and weather resistance and its realative lightweight nature. The natural wood grain that gets revealed through sandblasting adds SUCH a nice design element.
It is important that either product be repainted every five years or so to protect it from sun, rain, and freezing weather. With proper care, you can easily expect a wood sign to last +20 years. If protected from the environment, an HDU sign would have the same endurance.
Sandblasting is the same process for either material. We have a large industrial pot or round container on wheels that the blast media goes in. In this case, the blast media is fine sand. Separately, we have an industrial compressor that puts the sand under about 120lbs of pressure. The blast media is then forced through what looks exactly like a firehose. Ours has a 1/4" tungsten carbide orifice to protect if from the blast media. The result is a sand storm that makes it necessary to wear a breathing apparatus and protective clothing. It's a messy job. We still get sand in our hair and ears, even with the helmet. It is a highly skillful, manual process of eliminating just the right amount of wood for an even background pattern at a sufficient depth to give the sign dimension.
It is worth noting that the current turnaround for wood signs is about 6 weeks while HDU signs is half that.
Routing is a vastly different process than sandblasting. Whereas sandblasting is 100% skill, a CNC (computer numerical control) controlled machine runs a router that is fixed to a gantry. The computer tells the machine exactly how fast and where to move. It controls the gantry that holds the router and provides for three directions of movement, cutting the sign according to a program. The results with routing are precise and predictable. Other than setting up the program to run and correctly positioning the sign on the bed of the machine, there is little artistry in production.
On the otherhand, if there's artistry in the design then the question arises, does the background take away from the message more than it adds? We think it always adds. Sandblasting is like an Easter egg. What will the grain look like?!? It's an exciting process.
Options for drill bits include V-carve and flat-cut. With flat-cut bits, there is a sharp 90° angle in the bottom where the graphics grow upwards. It can give the sign a feeling of strength and boldness with a geometric feel (as compared to a sandblasted sign). V-carve bits are "V" shaped and can simulate a 3D landscape by varying the depths (also CNC controlled) of its cut path.
With more than 50 years of experience and working almost exclusively with wood signs, our partner Jimmy Lamb has come to appreciate the sandblasted wood sign above all. Sandblasted signs feel fluid and warm. One could say we offer the yin and yang of signmaking. Bold geometry vs. fluidity! Visit Jimmy: (here)
As our partner, Jimmy Lamb brings a strong sense of pride in his craft. He has the honorary title in Asheville of being the oldest original sign shop owner (still working his shop) in Asheville! Here's his router at work: 5' x 10' bed Check it out! We are delighted to offer Jimmy's services on his behalf and assure you, it'll be the same sign at the same price.
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