How is solid surface made?

When solid surface was discovered half a century ago, it was immediately clear that this material had a lot to offer. Since then, it has undergone rapid development, and its use has exploded. In this blog post, we explain the history of solid surface and delve into the manufacturing process.

How did solid surface come into being?

The inventor of solid surface is the American polymer giant DuPont, which surprisingly began as a gunpowder manufacturer. In 1967, the company introduced Corian, the first member of the solid surface family. Scientists led by Donald Slocum created Corian brand solid surface from polyacrylate and aluminum hydroxide, which is derived from the mineral bauxite. Once the building material's applications and strengths became clear, other companies quickly began developing solid surface variants. Well-known brands include Livingstone, Meganite, and Swanstone.

A stormy development

It started simply, but then solid surface underwent a meteoric rise. Starting with a base of marble and acrylic or polyester, solid surface eventually became available in hundreds of different colors and patterns, resembling marble, granite, or wood, for example. However different the appearance, the basic characteristics are always the same: non-porous (and therefore no bacterial buildup), highly durable and resistant, reusable, and malleable. Dozens of multinationals now produce (counter) tops, bathroom applications, and other types of solid surface.

The manufacturing process of custom solid surface

Customizing solid surface sounds easy enough, but it requires a great deal of specialized knowledge and expensive equipment. First, an acrylic or polyester resin is mixed with bauxite powder and dye. The material is then chemically mixed and heated to 60 degrees Celsius or higher, cut into sheets or shapes, and—depending on the brand—sanded or polished on one or both sides. Some manufacturers heat the solid surface to nearly 200 degrees Celsius and then cool it down again, as this makes it more heat-resistant.

Injection molding, custom solid surface production and finishing

Once the various raw materials have been mixed and processed into a solid surface, the solid surface (based on acrylic) can be injected into molds to create decorative or non-decorative shapes. This is called injection molding. The result is a solid surface piece without wrinkles or cracks. This piece is then cut to size by cutting, joining, and gluing. For this gluing (some also call it "welding"), pieces of the same material are always used, so it looks like a single piece, without wrinkles, cracks, or color variations. Then, all that remains is the finishing: sanding with a special type of sandpaper until the material has a very soft texture and a slightly matte appearance.

Professional work for professionals

Looking for a custom-made solid surface sink? The installation, finishing, and repair of solid surface products is a skilled job, best done by professionals. These craftsmen are known as "solid fabricators." For a seamless, seamless installation, they use machines and tools such as table saws, drills, templates, suction cups, and clamps. Solid surface can be completely customized. With our custom-made solid surface bathroom furniture, you'll bring a unique, top-quality sink into your home. Combine them with our high-quality stainless steel , black, or copper faucets to complete your bathroom.

Want to learn more about custom solid surface? Read more about solid surface maintenance here .