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I'm looking for a power tool for sanding/filing that can be used to shave down plastic. The two Dremel I have tend to melt the plastic even on the low setting and really aren't great for this task. Anyone know of a more delicate tool of this type?

 Slowroll wrote:
I'm looking for a power tool for sanding/filing that can be used to shave down plastic. The two Dremel I have tend to melt the plastic even on the low setting and really aren't great for this task. Anyone know of a more delicate tool of this type?

If you want to spend money, look into what Proxxon has to offer. Otherwise, the Dremel Stylo—which is what I use—will probably serve you just fine.

Which tool are you using if I may ask?

I've found that a fine grit sanding pad lightly touched to the surface is adequate for sanding down styrene or GW's plastic without significant melting. Naturally, the circular shape isn't always perfect for any detailed sanding, but perhaps this may be of some help if it's a defined edge or surface you need reduced. Disclaimer, if needed, is that this is a bit of a shaky proposal in that I guess it all depends on my personal technique and equipment - don't sail in all gung-ho on my account alone please!

Some Dremels (or any of the small power tools) that have a variable setting can still be quite fast on the lowest setting. As others have suggested, try a different bit. You may find one that cuts a bit more aggressively actually keeps the heat from building up and not melt your piece.

The only way I know to lower rpm on a rotary tool is to wire in lower power input.
So the motor spins slower with less juice.

I had 2 Dremels burnout on me, corded and cordless both. Guess sanding wooden knife handle was too much for the little guy.

got cheepo variable speed rotary tool from WEN.
Chinezium bits and build, But a nifty cable thingy that I use all the time.
slowest speed still at 8K rpm, that is alot.

To not melt plastic just tap the surface with the business end. If that is not enough then shop for specialty bits.

IMHO ! ! !
I think the problem is not the speed. Even if you have very slow, reduction geared slow speed higher torque rotor tool, with enough pressure even slower speeds will heat up work piece very quickly!
Perhaps proper abrasive bit is the key!

All bits that come with these rotary tools are for metal mostly, some for wood, and can be used for hard plastics.
That is why I think the abrasive surface for most bits is too (Fine)
With a proper bit that has channels for material to be channeled out, might be the way to go.
An angry, abrasive bit to eat out lots of material quick. Remove material quicker than it can melt, and then finish off the rough surface with hand files and sand papers.



Automatically Appended Next Post:
https://www.youtube.com/watch?v=wyQD6t0WA8g
Like this for with lower rpm motor,
or what as, voltage control reducer thing something something. Safety first!
https://www.youtube.com/watch?v=tXJOtWPPRwE

Honestly, powertools are not ment for the type of soft plastic that is beeing used in this hobby.

Shure you can make volt limiters to reduce rpm by reducing the amount of power that get to it(but then you need a single speed rotary tool), but by using thouse you shorten the lifespan of the motor by a fair amount.
plus thouse rotary tools are not designed for it, they are low torque high rpm, the faster they spin the more powerfull they become.

Dremel used to make and sell volt limiters but they quit it for the exact said reason.

(however i did came across an idea, modify a cheap electric toothbrush. cut off the bristle add a small base, then glue on some hi grade sandpaper to the base, like 500 or higer.
the motion from them should be enugh for the small scale sanding if you can find a way to make the sandpaper stick to the brush head while at the same time can be replaced...)

I use a polishing tool designed for nails/beauty.

Got it off amazon for about £13 works like a charm when normal files and sand paper cant reach.

Power drill? They run at a much lower rpm than rotary tools.

 Argive wrote:
I use a polishing tool designed for nails/beauty.

Got it off amazon for about £13 works like a charm when normal files and sand paper cant reach.

ooh, that's a good idea

 queen_annes_revenge wrote:
Power drill? They run at a much lower rpm than rotary tools.

Speaking of a drill!
https://www.youtube.com/watch?v=pLwAJEidpqo

Im surprised nobody mentions tamiya handing drill, it will do for most of the stuff, and its what I use for almost everything, for some items I have to switch to the proxon tool, but the proxon is still too fast even with the regulador.

A lot of the melting comes from the technique you use. If I'm not careful I can easily turn my bits into a lump of plastic in 2 seconds. But if I tap the edge of where I'm standing off and quickly drag off it buzzes through with no problem.




You also can walk down the nail polish aisle and buy an electric nail filler. Those are SUPER slow, I used to use one years ago before I got a real dremel. Works a treat if you're not in a hurry

 Argive wrote:
I use a polishing tool designed for nails/beauty.

Got it off amazon for about £13 works like a charm when normal files and sand paper cant reach.

I can second this. USB powered, adjustable speed and a selection of filing and polishing bits. Works perfectly on plastic, xps, milliput etc.

If you do not want to use Dremel you can try DEWALT DW660 Drywall or Proxxon 28500 12-Volt Rotary Tool. You can check info about these tools at https://themybuy.com/best-rotary-tools/. I have both and I am satisfied. But Dremel is also good but not for your needs as I see.

Power drill.

What bits are you using? A sander? If you want to remove material you should try carving burrs. I use them on my dremel to cut down resin components so I can use them in conversions. They cut the material away rather than friction like sanding, so don't tend to get hot.


Automatically Appended Next Post:

 Mothsniper wrote:
The only way I know to lower rpm on a rotary tool is to wire in lower power input.
So the motor spins slower with less juice.

I had 2 Dremels burnout on me, corded and cordless both. Guess sanding wooden knife handle was too much for the little guy.

got cheepo variable speed rotary tool from WEN.
Chinezium bits and build, But a nifty cable thingy that I use all the time.
slowest speed still at 8K rpm, that is alot.

To not melt plastic just tap the surface with the business end. If that is not enough then shop for specialty bits.

IMHO ! ! !
I think the problem is not the speed. Even if you have very slow, reduction geared slow speed higher torque rotor tool, with enough pressure even slower speeds will heat up work piece very quickly!
Perhaps proper abrasive bit is the key!

All bits that come with these rotary tools are for metal mostly, some for wood, and can be used for hard plastics.
That is why I think the abrasive surface for most bits is too (Fine)
With a proper bit that has channels for material to be channeled out, might be the way to go.
An angry, abrasive bit to eat out lots of material quick. Remove material quicker than it can melt, and then finish off the rough surface with hand files and sand papers.



Automatically Appended Next Post:
https://www.youtube.com/watch?v=wyQD6t0WA8g
Like this for with lower rpm motor,
or what as, voltage control reducer thing something something. Safety first!
https://www.youtube.com/watch?v=tXJOtWPPRwE

Dremels definitely seem to be reluctant to really get down and dirty with tougher materials. I've been making a leather stack knife handle and tried using cutter disks to remove the material, it was going nowhere. The little sanding tubes worked ok but took ages to remove anywhere near the material I wanted, and it just stops if you try to apply too much pressure.

 queen_annes_revenge wrote:
Power drill.

What bits are you using? A sander? If you want to remove material you should try carving burrs. I use them on my dremel to cut down resin components so I can use them in conversions. They cut the material away rather than friction like sanding, so don't tend to get hot.


Automatically Appended Next Post:

 Mothsniper wrote:
The only way I know to lower rpm on a rotary tool is to wire in lower power input.
So the motor spins slower with less juice.

I had 2 Dremels burnout on me, corded and cordless both. Guess sanding wooden knife handle was too much for the little guy.

got cheepo variable speed rotary tool from WEN.
Chinezium bits and build, But a nifty cable thingy that I use all the time.
slowest speed still at 8K rpm, that is alot.

To not melt plastic just tap the surface with the business end. If that is not enough then shop for specialty bits.

IMHO ! ! !
I think the problem is not the speed. Even if you have very slow, reduction geared slow speed higher torque rotor tool, with enough pressure even slower speeds will heat up work piece very quickly!
Perhaps proper abrasive bit is the key!

All bits that come with these rotary tools are for metal mostly, some for wood, and can be used for hard plastics.
That is why I think the abrasive surface for most bits is too (Fine)
With a proper bit that has channels for material to be channeled out, might be the way to go.
An angry, abrasive bit to eat out lots of material quick. Remove material quicker than it can melt, and then finish off the rough surface with hand files and sand papers.



Automatically Appended Next Post:
https://www.youtube.com/watch?v=wyQD6t0WA8g
Like this for with lower rpm motor,
or what as, voltage control reducer thing something something. Safety first!
https://www.youtube.com/watch?v=tXJOtWPPRwE

Dremels definitely seem to be reluctant to really get down and dirty with tougher materials. I've been making a leather stack knife handle and tried using cutter disks to remove the material, it was going nowhere. The little sanding tubes worked ok but took ages to remove anywhere near the material I wanted, and it just stops if you try to apply too much pressure.

Sorry I didn't see a response for a few days and lost track of this. I appreciate all the info!

The two Dremels I've got are a cordless multi speed 5-28k rpm, and a corded 2 speed, 15-35k. I had tried a few different sanding and grinding bits.

Anyways, you were right and it was the bit. The carving bit #194 does the work much more in line with what I was expecting. It does seem like it should be better though. Maybe I'll try the DeWalt, Proxxon or Milwaukee.

I bought one of these, the horrifical;y named "jeweller's flexible shaft". The foot pedal means I can get to extremely slow speeds.

I fundamentally reject that you cannot use power tools on plastic, I have and do. As do many others, such as this guy: https://www.youtube.com/watch?v=eScbVS4wJ60