Plastic Tumbling Media
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Bel Air’s plastic tumbling media is formulated for deburring, polishing, and surface preparation of aluminum, brass, copper, zinc, and plastic parts. Available in low-density, high-density hybrid, and synthetic formulations, it helps reduce distortion, impingement, and burr roll-over in vibratory and barrel finishing systems.
Use the media types, specifications, and selection charts below to compare grades, shapes, cutting action, and finish quality.
Available Media Formulations:
Available Plastic Media Types
Plastic Media Specifications
Low-Density Plastic Media
Bel Air’s low-density plastic media is formulated for surface preparation and improvement on aluminum, brass, copper, zinc, other metals, and plastics. Its lower bulk density helps reduce distortion, impingement, and burr roll-over while supporting applications ranging from fine pre-plate and pre-paint preparation to aggressive cut-down.
Choose low-density media when part protection and surface quality are especially important. Available grades allow users to balance cutting action, finish quality, wear, and cycle time for delicate components, general-purpose deburring, surface refinement, and finishing before plating, painting, or anodizing.
- Best choice for: delicate or thin-walled parts, soft metals, plastics, pre-plate and pre-paint finishing, and applications requiring reduced risk of impingement.
- Consider another media when: extremely hard materials or the shortest possible cycles require the greater mass and cutting energy of high-density hybrid or ceramic media.
| Grade | Cut Level | Finish Quality | Weight | pH | Color | Best For | Wear Rate** |
|---|---|---|---|---|---|---|---|
| R-400 | Very Light | Best | ~60 lb/ft³ | 7 | White | Precious metals, burnishing | 3-5% / 0.5-1.5% |
| R-500* | Light | Best | ~60 lb/ft³ | 7 | Natural | Zinc/aluminum pre-plate (special order) | 3-5% / 0.5-1.5% |
| R-600 | Light | Best | ~65 lb/ft³ | 7 | Green | Low Ra pre-polish on most metals | 3-5% / 0.5-1.5% |
| R-650 | Light-Medium | Better | ~65 lb/ft³ | 7 | Beige | Plastic parts pre-paint & metal prep | 3-5% / 0.5-1.5% |
| R-700 | Medium | Better | ~65 lb/ft³ | 7 | Red | General-purpose deburring | 3-5% / 0.5-1.5% |
| R-800 | Medium | Good | ~65 lb/ft³ | 7 | Blue | Fast burr removal, good surface finish | 3-5% / 0.5-1.5% |
| R-900 | Aggressive | Fair | ~75 lb/ft³ | 7 | Brown | Heavy cut-down, surface blending | 3-5% / 0.5-1.5% |
| R-1250 | Aggressive | Fair | ~70 lb/ft³ | 7 | Black | High stock removal (special order) | 3-5% / 0.5-1.5% |
*Special order grades.
**Wear Rate values reflect equipment type: High Energy systems (e.g., centrifugal finishers) vs. Low Energy systems (e.g., vibratory tumblers).
High-Density Hybrid Media (Plastic-Ceramic Blend)
Bel Air’s high-density hybrid media is a fast-cutting polyester formulation with an average bulk density of approximately 100 lb/ft³. Its increased density helps shorten processing cycles while producing refined surface finishes without hardening the metal surface. With proper water and compound flow, it also reduces foaming, promotes faster solids settlement, and provides clean processing on ferrous, non-ferrous, and plastic components. The media resists fragmentation and is available in more than 30 shapes and sizes.
It is a good intermediate choice when users need faster stock removal without the surface impact, risk of impingement, or potential contamination associated with some ceramic formulations.
- Best choice for: hard metals, aerospace components, faster cycles, low-Ra finishes, and applications requiring R-2000 HD’s aluminum-oxide-free formulation.
- Consider another media when: the part is extremely delicate, equipment capacity limits media weight, or only light cosmetic refinement is needed
| Grade | Weight | pH | Color | Best For | Wear Rate** |
|---|---|---|---|---|---|
| R-1000 HD | ~95 lb/ft³ | N/A | Tan | Shorter cycles, refined pre-plate finishes, very low RMS, clean processing, and fine finishing of metals and plastics | 7-10% / 1.0-2.5% |
| R-2000 HD | ~100 lb/ft³ | 7 | Gray | Extremely fast cutting on all materials; low-RMS and pre-plate finishes without aluminum oxide | 7-10% / 1.0-2.5% |
| R-3000 HD | ~100 lb/ft³ | 7 | Blue | Stainless steel, forgings, titanium, base metals, plastics, and very low-RMS finishes | 7-10% / 1.0-2.5% |
| R-4000 HD | ~95 lb/ft³ | 7 | Ivory | Low-Ra finishing of aerospace turbine and compressor blades, metals, and plastics | 7-10% / 1.0-2.5% |
**Wear Rate values reflect equipment type: High Energy systems (e.g., centrifugal finishers) vs. Low Energy systems (e.g., vibratory tumblers).
Synthetic Media (Urea Formaldehyde)
Synthetic media is a blend of urea-formaldehyde resin and abrasives. With an acidic pH of approximately 3, it provides clean, non-foaming processing with minimal surface residue. It can produce low-Ra, pre-plate finishes and is recommended for high-energy processing and finishing of delicate parts.
Proper compounding is required when processing non-ferrous metals to help prevent corrosion.
- Best choice for: delicate parts, high-energy equipment, clean processing, low-Ra finishes, pre-plate preparation
- Important considerations: acidic pH and proper compound selection when processing non-ferrous metals.
| Grade | Cut Level | Finish Quality | Weight | pH | Color | Best For | Wear Rate** |
|---|---|---|---|---|---|---|---|
| RUF-6 | Mildest | Best | ~60 lb/ft³ | 3 | Light Gren | Long-wearing, microcrystalline-silica media for pre-plate finishing. | 8-14% / 1.5-3.5% |
| RUF-7 | Mild | Better | ~65 lb/ft³ | 3 | Pink | Low-Ra finishing with good cutting action on metals and plastics. | 8-14% / 1.5-3.5% |
| RUF-8 | Medium | Good | ~70 lb/ft³ | 3 | Blue | Long-wearing media for deburring and surface improvement; slightly more aggressive than RUF-7. | 8-14% / 1.5-3.5% |
**Wear Rate values reflect equipment type: High Energy systems (e.g., centrifugal finishers) vs. Low Energy systems (e.g., vibratory tumblers).
Plastic Media Shapes & Sizes
Choosing the right media size and shape is essential for effective processing. Proper selection can prevent media lodging during tumbling and ensure proper separation after processing, resulting in more consistent finishing results.
Bel Air offers plastic media in a wide variety of preformed shapes and sizes, including:
| Shape/Description | Size (Inches) |  | |
|---|---|---|---|
| Cone shape media is the most versatile shape, providing uniform and effective finishing action on all surfaces with the exception of corners. | A | B | |
| 5/16 3/8 1/2 3/4 1 1-1/4 1-1/4 1-1/2 1-3/4 2 2 2-1/2 | 3/8 3/8 9/16 3/4 1 1-1/4 1-1/2 1-1/2 1-3/4 2 2-1/2 2-1/2 | ||
| Shape/Description | Size (Inches) |  | |
|---|---|---|---|
| Angle Cut Tristars have the basic capabilities of a triangle, along with sharp points for reaching into remote areas. A universal application media that can deburr hard to get at areas, such as gear teeth, slots or sharp corners | A | B | |
| 1-3/8 1-3/4 2 | 1/2 3/4 3/4 | ||
| Shape/Description | Size (Inches) |  | |
|---|---|---|---|
| Tri-cyls are a new and versatile shape suitable for use on a wide variety of surfaces. They have a cylindrical surface that mates well with concave surfaces, plus two flat surfaces that perform well on convex surfaces. TRI-CYLS combine strong points of triangles and cylinders, to penetrate into corners, slots and angles. | A | B | |
| 3/8 1-1/4 1-1/2 | 3/8 1-1/4 1-1/2 | ||
| Shape/Description | Size (Inches) |  | |
|---|---|---|---|
| 25° Angle Cut Cylinders are designed to improve finishing efficiency and results. The cylindrical shape provides a flowing action maximizing results. Best for use on concave surfaces, rounded areas, and holes. A durable shape for use on a wide variety of parts | A | B | |
| 1 | 9/16 | ||
| Shape/Description | Size (Inches) |  | ||
|---|---|---|---|---|
| Straight Cut Triangles provide maximum surface contact on flat surfaces. The straight shape gives a blocky action that helps maximize cutting action and penetrate into corners. | A | B | c | |
| 1/4 3/8 5/8 11/16 1 1-1/4 1-3/4 2-1/2 | 1/4 3/8 1/2 7/16 5/8 5/8 1-1/4 2-1/2 | 1/4 1/4 3/8 5/8 9/16 5/8 1-1/4 2-1/2 | ||
| Shape/Description | Size (Inches) |  | ||
|---|---|---|---|---|
| Tetrahedron combines the finishing action of a cone and a triangle. It is effective for parts with inside angles. | A | B | c | |
| 3/4 7/8 1-1/8 1-1/4 1-3/8 | 3/4 1/2 1-1/8 1-1/4 1-3/8 | 3/4 1/2 1-1/8 1-1/4 1-3/8 | ||
| Shape/Description | Size (Inches) |  | ||
|---|---|---|---|---|
| Pyramids provide multiple angles for effective finishing of parts with ridges and corners. The basic finish geometry of a cone shape with edges ¼” size comes to a point on top. | A | B | c | |
| 1/4 3/8 3/4 1 1-7/8 | 1/4 5/8 1-1/2 1-5/8 2 | 1/4 3/8 3/4 1 1-7/8 | ||
| Shape/Description | Size (Inches) |  | ||
|---|---|---|---|---|
| Wedges shape media otherwise known as BOWTIE shape gives the finishing action of a triangle but is effective when other shapes get lodges into parts. | A | B | c | |
| 1 1-5/8 2 | 3/4 1 1-1/4 | 3/4 1 1-1/8 | ||
Media Selection Charts
Cutting Aggressiveness
Cutting aggressiveness describes how quickly media removes material during tumbling or vibratory processing. Selecting the appropriate cut level helps achieve the required finish without excessive material removal or unnecessary changes to part geometry.
| Cut Level | Plastic Media Grades | Description |
|---|---|---|
| Mildest | R-400 R-500 RUF-6 | Light surface refinement; ideal for delicate components or pre-plate finishing. |
| Mild | R-600 R-650 RUF-7 R-4000 HD | Moderate cutting action; effectively removes light burrs without altering part geometry. |
| Medium | R-700 R-800 RUF-8 | Balanced cut; suitable for parts requiring moderate material removal and surface blending. |
| Fast | R-900 R-2000 HD R-3000 HD | Aggressive deburring; designed for heavy material removal and robust components. |
| Fastest | R-1250 R-1000 HD | Maximum cutting performance for shorter cycles, with grades available for either refined pre-plate finishing or aggressive cut-down. |
Finishing Quality
| Finish Quality | Grades |
|---|---|
| Fair | R-1250, R-900, RUF-8 |
| Good | R-700, R-800, RUF-7 |
| Better | R-600, R-650, R-2000 HD, R-3000 HD, R-1000 HD |
| Best | R-400, R-500, R-1000 HD, R-4000 HD, RUF-6 |
For optimal performance, pair plastic media with Bel Air Masterbrite finishing compounds:
| Compound | Description |
|---|---|
| MB #4A | Liquid, general purpose. Develops natural color on castings and produces clear, brilliant look. Conditions water and suspend soil. Excellent cut-down of any material using ceramic or plastic media low foam. 2-4 oz. per gallon. pH: 9-10.5 |
| MB #56 | Liquid ball burnishing compound for superior brightness on most metals. Excellent in combination with steel and porcelain type medias. 2-4 oz. per gallon. pH: 4.5 |
| MB #104 | Liquid, aluminum and titanium burnishing & cleaning. Removes oils and leaves bright polished surface. Also removes oxides from brass and copper. Use in soak tank or finishing applications. 2-6 oz. per gallon. pH: 1.0 |
Frequently Asked Questions
Synthetic plastic media is ideal when working with parts that demand precision finishing, minimal surface residue, or chemical compatibility with downstream processes like plating or coating. Compared to standard plastic media, synthetic options cut more gently but last longer and run cleaner.
You should choose synthetic media if you’re finishing small, delicate, or high-value parts—especially those made of non-ferrous metals or requiring low Ra finishes. It’s also great for high-energy finishing systems where clean operation is essential.
Ideal Situations:
- Parts with tight tolerance or mirror-like finish requirements
- When plating or coating follows finishing
- When reducing post-process cleaning steps is a priority
Bel Air can help you determine whether synthetic or standard plastic media is best for your process. Talk to a finishing specialist about your requirements and goals.
Yes, synthetic media can be used safely on non-ferrous metals—with the correct compound. Because it has an acidic pH (around 3), it must be paired with the right compound to prevent corrosion or surface etching.
When used properly, synthetic media delivers consistent, low Ra finishes and helps maintain the visual quality of brass, copper, and other sensitive alloys. It’s commonly used for pre-plate processing where surface purity matters.
Tips for Use:
- Always use a corrosion inhibitor with non-ferrous parts
- Monitor solution chemistry during long runs
- Rinse thoroughly after processing
Synthetic plastic media, made from urea formaldehyde resin, offers a unique combination of light cutting action and long life. It’s clean-running, non-foaming, and produces virtually no residue—making it ideal for finishing delicate components that require very low Ra values.
It’s also chemically stable and works well in high-energy finishing systems. This type of media is often chosen for fine polishing and deburring operations on precision-machined parts, especially when plating or coating is required afterward.
Advantages Include:
- Acidic pH for micro-cutting action
- Excellent for pre-plate surface preparation
- Stable in high-speed systems
In many applications, yes. High density plastic media can match or even exceed the performance of ceramic media in terms of cut rate—without the downsides like surface impingement or excessive edge rounding. It’s also much cleaner in process and easier to handle.
While ceramic media is still preferred for extremely heavy burr removal, high density plastic is ideal for parts that need both cutting and finishing in one step. It’s often used to cut process time in half while improving finish quality.
Consider High Density Plastic If:
- Parts are too delicate for ceramic
- A smoother finish is required
- Cycle time is a limiting factor
Bel Air customers have reduced cycle times by up to 50% using our high-density media. Send us your part or current media type and we’ll help you evaluate the switch.
Yes, high density plastic media is specifically formulated to handle hard materials such as stainless steel, titanium, and nickel alloys. It provides the cutting action needed to remove burrs or blend surfaces while avoiding the overly aggressive behavior of ceramic media.
It’s especially valuable in industries like aerospace, medical, and defense, where surface integrity and Ra values are critical. High density plastic media maintains consistent performance even on heavy parts with tight tolerances.
Best Uses:
- Surgical instruments
- Turbine blades and aerospace fasteners
- Engine components and stamped stainless parts
High density plastic tumbling media is a hybrid media that combines polyester resins with ceramic fillers to create a heavier, more aggressive formulation. It typically has a bulk density of around 100 lbs per cubic foot—35–50% denser than standard plastic media.
This added mass allows it to cut faster while still producing a refined finish, making it ideal for applications where both surface improvement and cycle time reduction are important. Despite its cutting strength, high density media doesn’t peen or harden the surface like ceramic can.
Typical Applications:
- Stainless steel or titanium parts
- Aerospace and medical components
- Parts requiring low Ra finishes in reduced time
Bel Air’s high-density formulations are engineered for speed and finish quality. Request a quote or sample to see how it performs on your parts.
Low density plastic tumbling media is available in a wide variety of shapes and sizes to suit different part geometries and finishing requirements. Common shapes include cones, triangles, pyramids, wedges, and cylinders. Each is designed to optimize contact with part surfaces and avoid media lodging.
Smaller media sizes (1/8″ to 1/4″) are typically used for parts with fine features, small holes, or internal passages. Larger sizes (1/2″ and up) are used for general deburring or finishing on larger components.
Media Selection Tips:
- Use smaller shapes for precision parts and hard-to-reach areas
- Choose larger shapes for general surface finishing and durability
- Avoid media lodging by matching shape to part design
Yes, low density plastic tumbling media is commonly used in pre-anodizing surface preparation. One of the key requirements for anodizing is a clean, uniform surface free from burrs or tool marks, and plastic media excels at producing this type of finish—particularly on aluminum parts.
Because plastic media is less likely to embed or alter the surface chemistry of the part, it helps ensure that anodizing layers form evenly and adhere properly. It also reduces the risk of contamination or discoloration that can occur with more abrasive media types.
Ideal For:
- Aluminum brackets and housings
- Extrusions and CNC-machined aluminum parts
- Die-cast aluminum components
Low density plastic media and ceramic tumbling media serve different purposes and are not interchangeable in most applications. Plastic media is significantly lighter, which means it is less aggressive and better suited for finishing soft or thin-walled parts without damaging edges or fine details.
In contrast, ceramic media is much heavier and denser, making it better for aggressive cutting or when working with hard metals like steel or titanium. However, ceramic can cause surface impingement, embedment, or even deformation on softer materials, which is why plastic media is preferred for aluminum, brass, and plastic parts.
Key Differences:
- Plastic media = gentle action; Ceramic media = aggressive cut
- Plastic is best for soft metals and pre-plate finishing
- Ceramic excels in heavy deburring and hard metal processing
Not sure whether plastic or ceramic is the better choice for your parts? Ask Bel Air for a media cross-reference or sample test—our team can help you decide.
Low density plastic tumbling media is ideal for surface finishing applications that require a balance between effectiveness and part protection. It is especially well-suited for deburring, deflashing, and smoothing operations on softer metals like aluminum, brass, copper, and zinc. These materials are more susceptible to damage during vibratory or tumbling processes, and the lower mass of plastic media helps to prevent impingement or distortion.
This media type is also commonly used on molded plastic parts to remove flash and polish surfaces without scratching. In many finishing lines, it is the go-to media for creating a pre-plate finish—especially when uniformity and surface integrity are critical.
Key Applications:
- Deburring die-cast aluminum components
- Pre-plate preparation for zinc parts
- Surface refinement of brass plumbing fittings
- Smoothing molded plastic housings
Need help selecting the right low density media for your application? Contact Bel Air for a media recommendation based on your part geometry and finish goals.
Ceramic and plastic tumbling media are both available in preformed shapes containing abrasive particles held within a binder. The abrasive type, particle size, binder, density, and formulation determine the media’s cutting rate, wear rate, and resulting surface finish.
Ceramic media is generally denser and capable of more aggressive cutting. It is commonly selected for:
- Deburring and edge radiusing
- Removing scale and machining marks
- Surface preparation
- Processing steel, stainless steel, and other relatively hard materials
Plastic media generally produces a softer cutting action and less impingement. It is commonly selected for:
- Deburring softer or more delicate parts
- Pre-plate and pre-paint surface preparation
- Producing smoother finishes
- Processing aluminum, brass, zinc, plastics, and other nonferrous materials
These are general guidelines rather than fixed rules. Ceramic formulations range from fine polishing to highly aggressive cutting, while plastic and synthetic formulations are available with different cutting rates and finishing characteristics. The correct choice depends on the part, required finish, equipment, geometry, and acceptable cycle time.