your confidence and skill before moving onto 3-D work. Thermoforming from a Designer Perspective For 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
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.
When bending acrylic surfaces the general rule of thumb for heating the material is 330 degrees F for about 10 to 12 minutes. The Growing Value of Thermoforming Thermoforming 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.”
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. I N T E R N AT I O N A L S U R FAC E FA B R I C AT O R S A SSO C I AT I O N
The same seems to hold true in Europe. Jeff Vickers, director of Solid Surface Solutions Co.,
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. Circle Reader Service #05 on the Reader Service Page or go to www.isfanow.org/info International Surface Fabricators Association • Vol. 4, Issue 1, 2011 • 25