I have been fighting that perennial lure builders dust problem for what seems like forever, and about a year back I thought I had it beat with a double 'cyclone' filter and a third automotive style filter in the vacuum cleaner, but NO, I was still blowing clods of dust from my more than adequate nose.
I disc sand all my blanks (so these are semi "hand carved" ) , this dust from the sander is very fine (like talc), so in the past 3 months I have been taking a different tack and have installed a ducted system on my sander and band saw (with 'blast gates'), where the dust is sucked away through 10cm ducts by an old (and large) evaporative cooler fan, which I have been hoarding for 'that special job' for the past 25 years.
These cooler fans spin pretty slow, so through a 10cm (4”) duct the 'suck' is pretty low but the volume is high, and is enough to get the finest dust away without the whining noise of a vacuum cleaner or 'cyclonic' dust extractor, just a low HUMMMM in your ears, you can even hear the phone ring.
With this setup I was getting all the dust away, but because it was so fine, again I was eventually getting it back with wind / fan draft etc.
So here is my solution , it seems to work well so far – I figured if I could just wet the dust it would drop and stick to the concrete, and when it dried it blew back at me ---- so I added a 'condenser' to catch the excess 'wet' dust which then drips into a tray, it uses about 10 L (5,5 Gal) of water / hour and so far no more 'BOOGIES' in the nose.
I was thinking larger ducting would be better but stuck with the10cm (4”) because - 1. I don't have the space and- 2. I think the air speed may be too high for the small amount of mister water to 'wet' the dust -
Air speed = in 8m/s—out 1.5m/s -- (OR --In 25' /sec ---- Out 5'/sec) –Reduced flow out is due to large exhaust duct = 34cm (apx 14”)
I have been using this for about 2 months now and it eats that deadly fine dust, just throw it on the garden when you have finished.
If I had the space I would use 15 Cm duct (6”) to increase the in flow, for saws etc.
Pete
Ducting
I used a lot of irrigation bits
Micro Spray head/nozzles( and collected dust (w/o condenser)
Dust trapped in water before condenser
With condenser screen
Dust after fitting condenser screen
Dry dust in screen