Basics of Solid Surface > Thermoforming Acrylic Solid Surfaces
Thermoforming Acrylic Solid Surfaces
We know that being informed on the characteristics and features of a product is pivotal when specifying for projects; domestic and commercial. That is why we make our certification and classifications publically available on our website and on all our platforms.
To give you a clearer picture of the standards of our products, we have created this page to briefly explain the benefits of Solid Surface.
Acrylic Solid Surfaces are Thermoformable. This gives Acrylic Solid Surfaces a flexibility that is hard to be matched by other solid surface products. The capabilities of Tristone are near limitless - the only limit is your imagination.
With Tristone, you can create curves and 3D shapes that can bring your designs to life. These curves can be worked to be smooth and natural to fit any aesthetic.
Allows for a smooth flowing design.
3D shapes are possible.
Maintains the same intensity of colour after being thermoformed.
The moulded pieces can be joined to create larger installations and displays.
How can Tristone Solid Surfaces be Thermoformed?
The chemical properties and composition of Acrylic Solid Surface gives Tristone its thermoforming capabilities. The process for thermoforming can vary depending on the product that is being manufactured.
Acrylic Solid Surfaces are usually heated to 150 degrees in a thermoforming oven until it becomes pliable and then moulded into intricate shapes and designs using a mould and a thermoforming press.
Key factors:
Preparing the Solid Surface for Thermoforming
The material must be slightly larger than the final dimension of the item that you are creating. This is because it is prone to shrinking after heating. Sand the edges of the surface to ensure there are no chips, cracks or scratches. This is because with time, small chips, cracks and scratches become a vulnerability area for cracks to form.
Heating Solid Surface
It is best to heat the entire piece of Acrylic. Heating a small section of the surface may cause stress to develop between heated and unheated areas. The material needs to be heated to the required temperatures to ensure that the Solid Surface can be formed evenly. Be careful not to heat the material too much or too little. Underheating may make the solid surface less flexible and prone to cracking or breaking. However, overheating may cause the surface to blister. After the material has reached the intended temperature, remove it from the thermoforming oven and bend it over or shape it into the desired form.
Material Flexibility
Every Acrylic Solid Surface material will have their own tolerances. As a general rule of thumb, acrylic material is the most flexible when it is heated to the appropriate temperature. A blend of acrylic and polyester is the next flexible, with an all-polyester material being the least flexible.
However, as the composition of Acrylic Solid Surface will differ, we recommend you refer to any guidance documents that are provided by the Solid Surface distributor.
Moulds
Male and female moulds can be created from Plywood or MDF. This will form the basis for the shape that you are trying to create. After the solid surface material is between the moulds, it should be left to cool while the material is held in place. This can be done by multiple means including a Thermoforming press.
Imperfections can form in the thermoformed Solid Surface if there are blemishes in the mould itself. These imperfections must be removed prior to placing materials on the mould.
Cool Down
The material must be fixed in place until it sufficiently cools. Once it has cooled to a sufficient amount, remove the restraints to allow the material to release stress.