Figure 4 - All storage racks must be visibly labeled with their weight loads.

How many surfaces can be heated in an oven, briefly cooled, and then shaped and twisted into countless designs?

Not many; and solid surface is one of the few. This makes solid surface a material with truly unlimited design potential.

Think about the possible applications of this technology. Thermoforming can produce furniture, sinks, bathtubs, cabinets, benches, lampshades and coved backsplashes. And that is only scratching the surface of the endless possibilities. Kitchen designs can really benefit from solid surface thermoforming. How about an island top with a thermoformed edge that drops to the floor? (See Figure 1.) That look gives a countertop design a high drama, one-of-a-kind look that adds tremendous value to the finished product.

I can’t over emphasize how important solid surface thermoforming is to our industry. The

beautiful lines and shapes that we create bring out the aesthetics of a design. Shapes are crafted that are pleasing to the eye and add to the daily enjoyment of using and living with the design. Who doesn’t enjoy it when their surroundings are as beautiful as they are functional?

The Process of ThermoformingMany people recognize that solid surface thermoforming can produce some really cool projects with unique selling opportunities, but may wonder how practical it is to attempt. Is it attainable for only a few select companies? To address these concerns, let’s look at the process of solid surface thermoforming a little more closely.

The key to thermoforming, as with any process, is to do your homework. It is always a good idea to talk with the manufacturer of the material to find out suggested procedures. You may

Taking a Look at Solid Surface Thermoforming By Jon Olson

Shop Management Matters

Figure 1 —This kitchen countertop with an eye-catching drop apron utilizes the thermoforming capabilities of solid surface to take this project beyond just another flat countertop surface.

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Figure 2 —When solid surface is thermoformed, it goes from a durable sheet to something the consistency of cooked spaghetti, and after cooling, once again retains the sought-after properties that has put solid surface among the premium surfacing options.

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also want to talk to fabricators who are familiar with the process. Additionally, be prepared to do some trial-and-error practice on scrap material. Thermoforming is both an art and a science, and hands-on work experience can’t be replaced.

There are really three types of solid surface material, acrylic, polyester and acrylic-polyester blend surfaces. Each type can be thermoformed, but the process will vary from material to material.

When bending acrylic surfaces the general rule of thumb for heating the material is 330 degrees

F for about 10 to 12 minutes. When it’s taken out of the oven it has the flexibility of cooked spaghetti (see Figure 2). The remarkable part of this is, after cooling for just 30 to 40 minutes, it is rock solid again and retains the strength of a flat piece of solid surface but in the new form it has been shaped to.

Please note, however, that heating times can vary greatly depending on the type of oven used. For instance, a convection-style oven, which circulates heat around the sheet, can take 45 minutes, while platen ovens, which have a heating element actually touching the material, are significantly faster.

When it comes to polyester material, it can be bent, but there are some restrictions when compared to acrylic solid surface. Polyester, for example, can’t be bent into the 3-D shapes you can achieve with an acrylic surface because it can be prone to tearing or even burning.

Also, material with larger particulates tends to have problems with those particulates popping out during the forming process. Additionally, polyester solid surface has different heating and cooling times than acrylic. The general rule of thumb for polyester-based solid surface is to reduce the heat by 30 degrees F and plan on heating the material 10 to 15 minutes longer

International Surface Fabricators Association • Vol. 4, Issue 1, 2011 • 23

Figure 3 — Vacuum forming heated solid surface material is a great way to achieve complex 3-D shapes.

available for thermoforming that come in different sizes and shapes. Smaller so-called “strip” ovens are typically used just for heating build-up pieces to be formed, whereas some ovens are large enough to accommodate an entire sheet of material that is 30-in.-wide by 144-in. long (see Figure 4).

Some ovens are similar in nature to those you would find in a home. Others can be opened by lifting the top section which is attached to the bottom section by hinges, mimicking the way

a clam looks, which is why they are referred to as “clamshells.” They have heating elements on both the top and the bottom part of the clamshell, and generally have a smaller footprint in the shop for space savings. Many times a vacuum table will be underneath the oven for even more economical use of space and easier transfer of material. Platen ovens would usually have the vacuum table next to the oven.

Good molds are as important as a good oven. If you minimize how strong a form needs to be while bending, you might crush the form under the stress a vacuum table puts on it. Also, whatever your mold looks like is what the piece of material will look like after it’s bent. The form will decide how successful you are with your solid surface thermoforming project. We should emphasize that a good knowledge of engineering, CAD design experience and mold-making skills are important if you’re to be successful in 3-D solid surface applications. I suggest starting slow, working on bends that aren’t as difficult. This will allow you to build

than acrylic. Of course, please make sure to check with your supplier of polyester sheet stock for its recommendations.

Acrylic-polyester blends of solid surface will fall somewhere between the two ends of the spectrum when it comes to thermoforming, depending on the exact content of the material. Generally speaking, the more acrylic included in the product, the shorter the heat times required and the more radical the bends can be. Once again, make sure to check with the supplier for recommendations on thermoforming.

There are different ways to form solid surfaces. Some ovens come with a vacuum table, which is very handy when working with complex 3-D bends (see Figure 3). But, these types of complex projects can also be done by building male and female forms or stand-alone bending forms. Some fabricators even form the material right to the project they are building.

There are many different types of ovens

24 • Vol. 4, Issue 1, 2011 • International Surface Fabricators Association

Figure 4 — Some thermoforming ovens, such as this platen-type system, are large enough to heat an entire 30- by 144-in. sheet of solid surface.

Good molds are as important as a good oven.

If you minimize how strong a form needs to be while

bending, you might crush the form under the stress a

vacuum table puts on it.

multiple parts.

Also, when approaching a fabricator to discuss a thermoforming job, ask what they have already made for forms. You may be able to design your project off of a mold already made that will lower the cost significantly. I hope that keeping in mind these tips will help you get you designs off the page.

The Growing Value of ThermoformingThermoforming in the solid surface segment of the industry is starting to move along at a rapid pace, and a lot of people are taking notice:“Thermoforming is a differentiator,” stated Russ Berry, president of A.S.S.T. a large commercial fabricator based in Hannover, Pa. “Thermoforming is valued by the design community. Young designers understand thermoforming and will be incorporating applications that require the technology. The industry needs more great fabricators embracing and using all of the attributes of solid surface. It’s not just a counter ... solid surface applications are growing.”

The same seems to hold true in Europe. Jeff Vickers, director of Solid Surface Solutions Co.,

a solid surface fabricator based in Sheffield, U.K., said, “We are seeing an increasing amount of designs which require advanced thermoforming skills. I believe this will continue to advance as more and more high profile projects are completed.” And from a manufacturer’s perspective, Joseph Elia, of Wilsonart Int’l, based in Texas, said, “In many ways I see our industry still looking at solid surface the way we did 10 years ago. Innovation and the way we use the material will define the next 10 years. The use of solid surface as a millwork material for instance is one of those ways. It’s time to go beyond countertops alone. The versatility of this material is only limited by one’s imagination ... Showing that to our customers will only strengthen our industry.” The scene of the solid surface world is changing rapidly. Convincing evidence of this can be seen at any trade show you may attend. Whether at ICFF, Neocon, KBIS or Green Build, the value of solid surface thermoforming is front and center. Designers are certainly taking note, the quotes are coming in and the sales are being made. Perhaps all fabricators aren’t yet ready to purchase their own thermoforming ovens, but why not collaborate with companies that already have one in the mean time? After all, solid surface thermoforming is what allows solid surface to have unlimited design potential, far beyond just flat countertops. INTERN AT ION AL SURFACE FABR IC AT ORS ASSOC IAT ION

your confidence and skill before moving onto 3-D work.

Thermoforming from a Designer PerspectiveFor designers who are thinking of developing a project using solid surface thermoforming, there are a few essential things to be aware of that will help bring a design to fruition.

First, for complex projects the cost to create the base form can be one of the largest expenses involved. The fabricator has to engineer the forms to fit your design. Many times, the type of 3-D form will require the use of a CNC machine to cut the parts. They also require skilled craftsmen to build them. All of this has to happen before you even get to the thermoforming part. This isn’t meant to scare you off, just to make you aware of what goes into the process.

Another important thing to remember is that most projects bent in a form still require some additional fabrication. As they cool, they may need pieces trimmed off so they can be properly seamed to other pieces. Keep this is mind as you design. Consider how many steps will be needed to create your design. More steps equal more labor which, of course, equals higher cost.

Some forms can be used as part of the project, such as in thermoformed walls. But forms that will be used more than once can give you a lot of bang for your buck. Offering thermoformed products that are repeatable in nature and can be incorporated into a variety of projects will allow you to amortize the cost of the mold over

Thermo-Forming Equipment for Solid Surface

www.schultzform.com USA 800-822-2875 Int. 928-345-8717

Schultz Form LLC has put durable forming equipment that is simple to use in your price range.Our Ovens and Vacuum Formers come in two basic sizes for Solid Surface material, but we are happy to custom make any size needed, from shower pan ovens to strip ovens.Manufacturing Thermoforming equipment is more than our specialty…Itʼs all we do and weʼre good at it.Let us help you.

International Surface Fabricators Association • Vol. 4, Issue 1, 2011 • 25

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When bending acrylic surfaces the general rule of thumb for heating the

material is 330 degrees F for about 10 to 12 minutes.