Countertop Fabrication

Counter Fabrication and Design

Countertop fabrication with solid surface materials—such as Corian®, Avonite®, or HI-MACS®—is a detailed and precise process that transforms raw sheets of engineered material into custom-fit countertops.

Solid surface materials are composed primarily of acrylic or polyester resins combined with natural minerals, creating a non-porous, seamless, and highly workable product ideal for kitchens, bathrooms, and commercial environments.

The fabrication process begins with templating. Installers visit the site to measure and create a precise template of the countertop layout. This template includes dimensions, cutouts for sinks and cooktops, and any special design elements such as curves, integrated backsplashes, or waterfall edges. The template ensures the final product will fit exactly, even in irregular or older spaces where walls and cabinets may not be perfectly square.

Once the template is finalized, fabrication takes place in a workshop. Solid surface sheets—usually ½ inch thick—are cut to size using specialized saws or CNC machines for complex shapes and precise cuts. Edges are shaped with routers to create profiles ranging from simple bevels to more decorative bullnose or ogee edges. If the design includes curves or custom features, the material may be thermoformed by heating it in an oven until pliable, then shaping it over a mold.

Seams are joined using a color-matched acrylic adhesive that chemically bonds the pieces. After curing, the seams are sanded until completely smooth, resulting in a virtually invisible joint. This seamless look is a key advantage of solid surface materials and is particularly beneficial for integrated sinks, drainboards, or long runs of counter space.

After assembly, the entire surface is sanded to achieve the desired finish—typically matte, satin, or high-gloss. This finishing process also removes any minor scratches or imperfections, leaving a clean, uniform appearance.

The fabricated countertop is then transported to the installation site, where it is carefully fitted, secured to the cabinetry, and final adjustments are made. Plumbing fixtures are reconnected, and the installation is finished with sealing or caulking as needed.

Solid surface countertop fabrication is labor-intensive and requires skilled craftsmanship, but the result is a highly customizable, hygienic, and repairable surface that suits both residential and commercial spaces.