Why require two measured anchors?

A generic rule of thumb cannot capture the combined effect of your media, substrate, pressure, angle, distance and technique. Two trials bound the range where interpolation is defensible.

What happens outside the range?

The selected size is clamped to the nearest measured anchor and a warning is raised. The calculator does not invent an extrapolated profile beyond your trials.

Does the estimate guarantee acceptance?

No. Process variation and measurement uncertainty can still produce readings outside the coating window, so production inspection remains required.

Can I use nominal mesh size?

Only when both calibration anchors and the selected media use the same documented particle-size basis, because mesh numbers are not directly comparable.

Abrasive Blasting, Shot Peening & Surface Prep calculator

Calibrated Abrasive Blast Surface Profile Estimate

Interpolate surface profile from two measured shop calibration points instead of a generic rule of thumb. Enter both trial sizes and profiles plus the selected media size; the model never extrapolates past the measured range.

What this calculator does

Surface profile interpolated between two measured shop calibration anchors, without extrapolating past the measured range.

Formula used

Calibration slope = (high profile − low profile) ÷ (high media size − low media size)
Estimated profile = low profile + (selected size − low size) × slope
Profile increase = estimated profile − low measured profile
Selected size is clamped to the range between the two measured anchors

Inputs explained

Low Calibration Media Size: Particle-size measure from the lower calibration trial.
Low Calibration Measured Profile: Profile measured at the lower calibration size.
High Calibration Media Size: Particle-size measure from the upper calibration trial.
High Calibration Measured Profile: Profile measured at the upper calibration size.
Selected Media Size Measure: Comparable particle-size measure for the planned media.

How to use the result

Best suited to trial-blast planning, media-size selection, calibration review.
No extrapolation beyond the measured calibration anchors. Does not replace surface-profile inspection on production work. Not transferable across substrate, media shape or machine settings without new trials.

Common questions

Why require two measured anchors? A generic rule of thumb cannot capture the combined effect of your media, substrate, pressure, angle, distance and technique. Two trials bound the range where interpolation is defensible.
What happens outside the range? The selected size is clamped to the nearest measured anchor and a warning is raised. The calculator does not invent an extrapolated profile beyond your trials.
Does the estimate guarantee acceptance? No. Process variation and measurement uncertainty can still produce readings outside the coating window, so production inspection remains required.
Can I use nominal mesh size? Only when both calibration anchors and the selected media use the same documented particle-size basis, because mesh numbers are not directly comparable.

Last reviewed 2026-10-01.