Product Positioning

Flexible Discs for Curves, Coatings and Scratch Uniformity

Sponge sanding discs are positioned as soft-flex discs in the disc sanding category, designed to improve contour conformity, reduce gouging risk, and enhance scratch uniformity. They are especially suitable for coatings, fillers, primers, wood surfaces, and slightly contoured parts requiring consistent finishing quality.
They are not for aggressive stock removal, but for making surfaces smoother, more uniform, and ready for coating—critical in pre-paint prep and cosmetic finishing.

 

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Technical Specifications

Configurable by Diameter, Foam Density and Attachment

Item	Specification
Product Type	Sponge sanding discs
Backing	Foam interface + Abrasive face
Diameter	3″ / 4″ / 5″ / 6″ (75–150 mm)(Extendable)
Attachment	Hook & Loop (Velcro) / PSA (Self-adhesive)(Optional)
Grit Range	P80 – P600 (Extendable)
Foam Density	Soft/Medium/Hard (Customizable)
Color & Form	Customizable
Max RPM	Marked per size & standard

 

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Processing Logic

Soft Contact Redistributes Pressure

Standard paper discs concentrate pressure on curves and edges, risking gouging, burn-through, or deep scratches. Sponge discs use foam buffering to redistribute pressure into a more uniform contact area:

• Better contour conformity and scratch consistency;
• Gentler edge interaction with lower burn-through risk;
• Ideal for pre-paint finishing and scratch unification.

 

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Backing Structure & Performance Limits

Smoother, Not the Fastest Removal Tool

• Strengths: contour following, edge-friendly contact, strong scratch consistency
• Limits: slower stock removal than hard-backed discs or belts; heavy defects should be removed first with standard discs/belts

Foam compresses under load—excess pressure increases heat, foam fatigue, and uneven scratch patterns (especially at high RPM)

 

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Machine Compatibility & Operating Conditions

Orbital / Random Orbital Sanders—Controlled Pressure is Key

• Machines: orbital/random orbital sanders, selected handheld sanders
• Recommended conditions: medium to low pressure, stable speed, continuous movement
• Attachment: primarily hook & loop; PSA options available upon request
• Note: dust extraction improves cleanliness and reduces loading (depending on structure)

 

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Engineering Comparison

Comparison	Sponge Discs	Standard Paper Discs	Mesh Discs
Contour conformity	★★★★★	★★★	★★★★
Edge gouging risk	Low	Medium–High	Medium
Scratch uniformity	Excellent	Medium–Good	Good
Anti-loading on fillers	Medium–High (structure-dependent)	Medium	High
Dust extraction friendliness	Medium	Medium (hole-based)	High

 

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Typical Applications & Industries

Automotive, Wood and Coating Prep Workflows

• Automotive refinishing: filler sanding, primer finishing, pre-paint prep
• Wood/furniture: sealer/primer finishing, edge blending
• Industrial coating: defect correction and surface preparation
• Cosmetic parts: scratch unification on slight contours and edges

 

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Range & Recommended Use

Grit Strategy for Coatings and Contours

Typical recommendation

• P80–P120: initial leveling of filler/thick coatings (control pressure to reduce loading)
• P150–P240: intermediate finishing and scratch unification (most common)
• P320–P600: primer finishing and final pre-paint prep (appearance-first)

 

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OEM & ODM Capability

Foam Engineering for Target Surfaces

OEM/ODM supported: foam hardness/thickness, diameter and hole/no-hole designs, abrasive system and grit combinations, hook & loop/PSA options, colors and packaging, and process-based kit programs—engineered for different contours, coatings, and cosmetic targets.

 

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Why Choose Us

Sponge Performance Depends on Foam Density, Bonding and Batch Stability

Sponge disc performance depends on foam density/resilience, composite bonding, and abrasive distribution stability. Foam controls pressure distribution and edge behavior; bonding and abrasive control life and scratch consistency. We engineer for batch stability to make pre-paint prep repeatable.

 

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Usage & Storage Recommendations

Avoid Over-Pressure—Let the Foam Work

• Use medium to low pressure with stable speed and continuous movement to avoid compressing the foam and creating heat/uneven scratches
• For fillers/coatings, use dust extraction and periodic cleaning to reduce loading
• Avoid heat and solvent exposure to prevent foam aging and bond failure
• Store dry and shaded; avoid moisture and compression; reseal after opening