Synthetic Tumbling Media

Synthetic Media | Synthetic Tumbling Media for Deburring and Smooth Finishing

Synthetic Tumbling Media is formulated for long wear when deburring metals such as brass and aluminum. Its lighter weight compared with many other tumbling media makes it well suited to soft metals and applications where a smooth surface finish is important.

Synthetic Media can provide polishing through moderate cutting action while producing low residue and minimizing chipping and breaking. It is available in multiple shapes and sizes, allowing the finishing process to be matched to part geometry, material, and the required surface result.

Synthetic Media for Soft Metals

Soft metals require a finishing approach that removes burrs and machining marks without creating unnecessary scratches, excessive edge rounding, or surface damage. Synthetic Tumbling Media is particularly suitable for aluminum, brass, and other non-ferrous materials where a lighter finishing action is preferred.

Kramer Industries offers several synthetic bonds for different finishing requirements. KSM is a polishing bond for a bright polish on softer metals such as aluminum and brass. KSV is a pre-plate bond designed to produce extremely fine, matte finishes and excellent color. KSX provides general-purpose cutting ability while leaving a finish suitable for plating or painting.

The lighter bulk density of Synthetic Media provides more media volume per pound than denser ceramic alternatives. This characteristic can be useful when processing softer materials or when a smoother finishing action is required.

Finishing Options and Synthetic Media Bonds

The available bond determines how aggressively the media works and the type of finish it produces. KSW is a general-purpose formulation designed as an alternative to KX Plastic Media, providing good cutting properties with less residue and lower cost than the KX formulation and a longer lifetime than KSX Synthetic media.

KSY is a fast-cutting formulation designed for non-ferrous parts when metal removal, deburring, radiused edges and corners, and shorter cycle times are important. These different formulations allow the finishing process to be adjusted without changing the basic equipment setup.

Synthetic Media can be selected for polishing, pre-plate finishing, general-purpose work, or faster cutting depending on the bond. The appropriate formulation should be based on the part material, starting condition, required finish, and desired cycle time.

Shapes and Sizes for Different Parts

Synthetic Tumbling Media is available in cones, cylindrical wedges, pyramids, tetrahedrons, triangles, tristars, and wedges. These shapes provide different contact patterns and can be selected according to the geometry of the workpiece.

Smaller media can reach narrow areas and detailed features, while larger shapes can provide broader contact on more open surfaces. Media size should also be selected carefully around holes, slots, and recesses to reduce the possibility of lodging.

Kramer Industries provides multiple dimensions across the available synthetic shapes and bonds. Standard and non-standard availability varies by shape, size, and formulation, so the product specifications should be checked when selecting a specific configuration.

Applications for Deburring and Surface Finishing

Synthetic Tumbling Media can be used for deburring brass and aluminum, polishing metals and plastics, edge rounding on plastics and other materials, eliminating machining lines, forming a light radius, pre-plate finishes, disc finishing, and high-energy finishing.

Synthetic Media is particularly useful when a smooth finish and controlled cutting action are more important than aggressive material removal. For soft metals, a lighter finishing action can help reduce the risk of unnecessary surface damage while still removing burrs and machining marks.

For pre-plate work, the selected bond should provide the surface condition required before the next coating or plating stage. A polishing bond may be appropriate when appearance is the priority, while a general-purpose or fast-cutting bond can be considered when more material removal is needed.

Synthetic Media Compared With Other Tumbling Media

Synthetic media has a lower bulk density than ceramic and is generally less aggressive. Ceramic media is commonly selected for harder materials such as steel, stainless steel, and titanium, while synthetic and plastic media are commonly used with softer metals such as aluminum, brass, copper, and zinc.

For steel parts, the media choice should be based on the required amount of material removal and the desired finish. Synthetic media may be suitable for lighter finishing requirements, but more aggressive ceramic media is generally considered when substantial deburring or stock removal is required.

The term synthetic polishing media describes media used to produce polished or refined surfaces, while synthetic parts finishing media is a broader term covering deburring, edge rounding, pre-plate preparation, and other finishing operations. Synthetic polishing media is generally selected when surface appearance is a primary objective, while synthetic parts finishing media can cover a wider range of finishing stages.

Choosing the Right Synthetic Finishing Media

The right media depends on four main factors: the workpiece material, part geometry, desired surface finish, and required cycle time. Media shape and size should then be selected to provide effective contact without becoming trapped in part features.

Synthetic Media is a useful option when the application requires moderate cutting action, low residue, and a smooth finish. The lighter bulk density also provides greater volume per pound than heavier media types, which can be useful when operating costs and media consumption are considered.

Synthetic screen media and synthetic filter media are different product categories and should not be confused with synthetic tumbling media. Screen media is generally associated with screening or separation applications, while filter media is used for filtration. They do not perform the same surface-finishing function. Synthetic screen media is intended for screening or separation rather than part finishing, while synthetic filter media is intended for filtration rather than deburring or polishing. A synthetic screen media product therefore serves a different purpose from the media used to finish manufactured parts.

Kramer Industries can help identify a suitable synthetic bond and shape when the finishing requirement depends on part material, geometry, or surface condition. Kramer Industries can also help compare formulations when the application requires a particular balance of cutting action, finish, and media life.

Synthetic Media Bond Description

KSM – Polishing (Pink)

Light weight media that delivers a bright polish on softer metals such as aluminum and brass. Long-lasting and performs well in all types of mass finishing equipment.

KSV – PRE-PLATE (Light Green)

A long-lasting media that produces extremely fine, matte finishes and excellent color.

KSX – GENERAL PURPOSE (Pink)

Good cutting ability yet leaves a finish that can be plated or painted. Formulated for high-energy equipment.

KSW – GENERAL PURPOSE (Tan)

Designed as an alternative to KX Plastic Media. Offers good cutting properties with less residue and lower cost than the KX formulation and longer lifetime than the KSX Synthetic media.

KSY – FAST CUTTING (Tan)

A light weight, aggressive media formulated for non-ferrous parts where metal removal, deburred and radiused edges and corners, and shorter cycle times are of primary concern.

Dimensions		Formulations / Bonds Bond Descriptions
A	B	KSM	KSV	KSX	KSW	KSY
		Polishing (Pink)	Pre-Plate (Light Green)	General Purpose (Pink)	General Purpose (Tan)	Fast Cutting (Tan)
3/8“	3/8“	NS	S	S	S	NS
1/2“	9/16“	NS	S	S	S	NS
5/8“	7/8“	NS	NS	NS	NS	NS
3/4“	3/4“	NS	S	S	S	S
1″	1″	NS	NS	NS	NS	NS
11/4“	11/4“	NS	S	NS	S	NS
11/2“	11/2“	NS	NS	NS	NS	NS
SDS

S = Standard stock item (50 lb minimum order)
NS = Non-Standard stock item (Due to production scheduling, this item may be in stock – Please Contact Us For Availability – If not in stock, a minimum order of 500 lbs is required for manufacture)

Cylindrical Wedges

Dimensions		Formulations / Bonds Bond Descriptions
A	B	KSM	KSV	KSX	KSW	KSY
		Polishing (Pink)	Pre-Plate (Light Green)	General Purpose (Pink)	General Purpose (Tan)	Fast Cutting (Tan)
3/4“	3/4“	NS	NS	NS	NS	S
11/2“	11/2“	NS	NS	NS	NS	NS
SDS

S = Standard stock item (50 lb minimum order)
NS = Non-Standard stock item (Due to production scheduling, this item may be in stock – Please Contact Us For Availability – If not in stock, a minimum order of 500 lbs is required for manufacture)

Pyramids

Dimensions			Formulations / Bonds Bond Descriptions
A	B	C	KSM	KSV	KSX	KSW	KSY
			Polishing (Pink)	Pre-Plate (Light Green)	General Purpose (Pink)	General Purpose (Tan)	Fast Cutting (Tan)
3/8“	3/8“	3/8“	NS	S	S	S	S
3/8“	5/8“	3/8“	NS	NS	S	S	S
15/8“	1″	1″	NS	NS	NS	S	S
SDS

S = Standard stock item (50 lb minimum order)
NS = Non-Standard stock item (Due to production scheduling, this item may be in stock – Please Contact Us For Availability – If not in stock, a minimum order of 500 lbs is required for manufacture)

Tetrahedrons

Dimensions		Formulations / Bonds Bond Descriptions
A	B	KSM	KSV	KSX	KSW	KSY
		Polishing (Pink)	Pre-Plate (Light Green)	General Purpose (Pink)	General Purpose (Tan)	Fast Cutting (Tan)
3/4“	3/4“	NS	S	S	S	S
11/8“	11/8“	NS	S	NS	S	S
2″	2″	S	NS	NS	NS	NS
3″	3″	NS	NS	NS	NS	NS
SDS

S = Standard stock item (50 lb minimum order)
NS = Non-Standard stock item (Due to production scheduling, this item may be in stock – Please Contact Us For Availability – If not in stock, a minimum order of 500 lbs is required for manufacture)

Dimensions			Formulations / Bonds Bond Descriptions
A	B	C	KSM	KSV	KSX	KSW	KSY
			Polishing (Pink)	Pre-Plate (Light Green)	General Purpose (Pink)	General Purpose (Tan)	Fast Cutting (Tan)
11/4“	7/8“	5/8“	NS	NS	NS	NS	NS
SDS

S = Standard stock item (50 lb minimum order)
NS = Non-Standard stock item (Due to production scheduling, this item may be in stock – Please Contact Us For Availability – If not in stock, a minimum order of 500 lbs is required for manufacture)

Tristars

Dimensions		Formulations / Bonds Bond Descriptions
A	B	KSM	KSV	KSX	KSW	KSY
		Polishing (Pink)	Pre-Plate (Light Green)	General Purpose (Pink)	General Purpose (Tan)	Fast Cutting (Tan)
2″	1″	NS	NS	NS	NS	NS
SDS

S = Standard stock item (50 lb minimum order)
NS = Non-Standard stock item (Due to production scheduling, this item may be in stock – Please Contact Us For Availability – If not in stock, a minimum order of 500 lbs is required for manufacture)

Wedges

Dimensions		Formulations / Bonds Bond Descriptions
A	B	KSM	KSV	KSX	KSW	KSY
		Polishing (Pink)	Pre-Plate (Light Green)	General Purpose (Pink)	General Purpose (Tan)	Fast Cutting (Tan)
1″	3/4“	NS	NS	S	S	S
11/2“	1″	NS	NS	NS	S	S
2″	11/4“	NS	NS	NS	NS	NS
SDS

S = Standard stock item (50 lb minimum order)
NS = Non-Standard stock item (Due to production scheduling, this item may be in stock – Please Contact Us For Availability – If not in stock, a minimum order of 500 lbs is required for manufacture)