Solid surface fabrication: The process explained

• 10 May 2025|
• Blogs|
• velstone_admin

What is solid surface fabrication, and why does it matter to professionals?

Solid surface fabrication is the meticulous process of transforming high-performance solid surface materials into custom-designed products such as kitchen worktops, reception desks, and surfaces for residential and commercial applications. For architects, designers, and specialist fabricators, understanding each step is essential to ensure the best results, both visually and structurally.

At Velstone, we deliver a seamless solid surface fabrication process, starting with premium material selection, followed by cutting, shaping, bonding, and polishing, resulting in durable, hygienic, easy-to-install solutions trusted across healthcare, hospitality, education, and more.

The solid surface fabrication process

1. Material Selection

A high-quality end product starts with high-quality materials. Velstone’s solid surface materials are non-porous, 100% silica-free, and available in a wide range of colours, enabling tailored designs with long-term peace of mind.

Key benefits of Velstone solid surface materials:

• Durable and resistant to daily wear and tear
• Hygienic and easy to clean
• Silica-free, ensuring a safer fabrication environment
• Versatile with a wide design palette for every application

2. Cutting

Fabrication begins with precise machining and cutting using advanced CNC machinery for precision engineering. Our years of experience in solid surface manufacturing means Velstone can be supplied and delivered at scale while maintaining accuracy and quality consistency across entire projects thanks to a consistent factory finish.

3. Shaping and Thermoforming

One of the most powerful aspects of solid surface fabrication is its adaptability. Velstone is the only manufacturer to offer Modified Acrylic and 100% Acrylic option. The full Acrylic material can be heated and thermoformed into a variety of shapes, brining curves and contours to life and allowing designers and architects to unleash creativity in even the most challenging spaces, including anything from curved reception desks to seamless integrated sinks.

4. Bonding and Jointing

A core aspect of solid surface fabrication is its ability to create long, continuous spans of material with near-invisible joints. Velstone’s advanced bonding techniques guarantee a smooth, seamless appearance and structural reliability.

5. Finishing and Polishing

After the surface is cut, shaped, and bonded, it’s time to bring out its natural aesthetic with professional finishing for the final touch of craftsmanship, including hand-sanding for a flawless finish and a final inspection for quality assurance.

Solid surface fabrication: Where precision meets performance

A Unique 25mm Surface

Velstone’s 25mm solid surface offers a smarter, more efficient alternative to conventional 13mm surfaces that require an MDF substrate for support. With built-in mechanical strength and superior fire resistance, the 25mm thickness eliminates the need for additional materials or complex fabrication. Unlike thinner options, which often demand costly outsourcing to specialist fabricators, Velstone’s surface can be machined on-site or supplied pre-finished, saving both time and money. This innovation is especially beneficial for furniture makers, who typically lack the tools or capacity for advanced worktop fabrication.

Installation – Ready-to-use

Unlike conventional materials that require time-consuming on-site modifications, Velstone’s solid surface worktops are machined to drawings and manufactured to customer’s specifications and supplied ready to install, saving significant time and labour on-site, while larger worktops are manufactured into smaller, more manageable pieces (typically up to 3 metres), pre-fabricated and polished. And no need for an MDF substrate or third-party support also significantly reduces installation time.

Repair and Maintenance – Built to Last

Velstone’s 25mm thick solid surface is built for demanding conditions thanks to being a non-porous, easy-to-clean, and highly durable surface which is resilient to against chipping and staining. It is also onsite repairable; in cases where damage does occur, we provide easy-to-use repair kits that make it easy to restore surfaces to their original condition, ensuring continuous use without the need for costly replacements.

Applications Across Sectors – From Kitchens to Cruise Ships

Whether for an architect or specifiers vision in a luxury residential application or a high-traffic commercial sector project, Velstone surfaces stand up to both form and function. The fabrication and installation process of Velstone is it has been used across a wide variety of sectors. It has been used for:

• Reception desks in corporate or healthcare environments
• Laboratory and educational surfaces in schools and universities
• Modular bathrooms, student accommodation, airports, cruise ships and more
• Kitchen worktops in homes and hospitality

Why do fabricators trust Velstone?

As a specialist solid surface fabricator, Velstone makes fabrication easy thanks to:

• Homogeneous material that machines cleanly
• No additional substrate needed
• Delivered pre-polished, pre-jointed, and ready to install
• A fast turnaround, ideal for tight project timelines
• Technical support from start to finish

Custom Design Flexibility

With an extensive colour palette and ability to manufacture to bespoke thicknesses and dimensions, Velstone can be tailored to meet the most exacting design requirements and enables complete creative freedom without compromising performance. Design advantages include seamless colour matching and advanced CNC capabilities for complex shapes.

Supporting Sustainable, Safe Projects

Velstone is 100% silica-free, significantly reducing health risks during fabrication and installation, providing peace of mind and setting us apart from quartz-based or granite composite materials that have come under scrutiny. Velstone is a rigid plastic, non-porous, and completely hygienic to machine and use. This fundamental difference means that Velstone products do not carry the risks associated with crystalline silica inhalation during processing or installation.

The longer life cycle of Velstone compared to other traditional surface materials also means that it will not need to be replaced as quickly, making it the sustainable choice.

Why choose Velstone for solid surface fabrication?

Velstone has earned its reputation through precision manufacturing using high-quality materials, rigorous testing and design flexibility. With 25-plus years of experience in solid surface fabrication and a 25mm thick surface that doesn’t require complex support, is delivered pre-finished, saving time and cost, and is ideal for both residential and commercial sector applications, it’s easy to see why Velstone is the preferred solid surface choice for professionals who demand the best.

Contact a member of our team today to discuss specifying Velstone on your next large-scale project or request a free sample.