Thermoform Fabricators

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Thermoforming is a process in which Solid Surface material is heated to a pliable state, allowing it to be shaped and moulded into complex curves and contours. This process is ideal for creating custom, seamless designs and detailed features in benchtops, sinks, reception counters and other surfaces.

No, unlike engineered stone, Solid Surface does not contain any Silica and the manufacture of Solid Surface products does not create health issues for those working within the industry.

Solid Surface benchtops are renowned for their exceptional resilience, typically lasting anywhere from 15 to 20 years or even longer with proper care and maintenance. This versatile material not only stands the test of time but can also be re-manufactured into new surfaces at the end of its life, making it a sustainable and smart investment for long-term use.

Warranties for Solid Surface benchtops vary by brand, but typically cover manufacturing defects and material quality for up to 10 years. We recommend reviewing the specific warranty terms provided with your purchase and on (warranty page) ensure you have a clear understanding of the coverage.

Solid Surface sheets are commonly available in thicknesses of 6mm, 12mm, and 19-20mm. For most projects, 12mm is typically used. Thanks to the seamless nature of Solid Surface, the junction where the edge meets the top is difficult to detect, providing a sleek and continuous look, regardless of the edge height.

Almost all Solid Surface materials can be thermoformed, though there are some limitations. These include the tightness of the radius for certain colours. If any issues arise, we will make sure to highlight them in your quote or discuss them with you before proceeding with the estimate.

Yes, scratched Solid Surface benchtops can often be refinished. Minor scratches can typically be buffed out using fine abrasives. For deeper scratches or more significant damage, a professional refinishing service may be needed to restore the surface to its original condition. See do it yourself sanding

Absolutely! When properly joined, seams can be virtually invisible with many colour options. However, for veined colours, achieving a perfect design match on both sides of the seam is not possible, and the veins may not align exactly across the join, thus making the join visible.

Yes, Solid Surface can be used for outdoor installations. However, some colours are more UV stable than others. In general, lighter colours tend to perform better in terms of UV stability.

Yes, Solid Surface is highly stain resistant due to its non-porous nature, which makes it less likely for liquids and stains to penetrate the surface. However, it’s still recommended to clean spills promptly, especially those from strong chemicals or dyes, using warm, soapy water.

Solid surface sheets can tolerate moderate heat, and heat plays a crucial role in the thermoforming process. However, we recommend using trivets or heat pads to protect the material. Repeated or excessive heat can cause expansion and contraction, potentially leading to joint separation or cracking. Please note that heat damage is not covered under warranty.

Yes, solid surface is non-porous, making it an excellent choice for wet areas. It’s commonly used for integrated sinks, wash planes, and splashbacks in bathrooms and other high-moisture environments. However, it’s important to apply a waterproofing agent behind the solid surface in the appropriate areas to comply with the Waterproofing Standard AS 3740:2021.

Yes, solid surface can be damaged by harsh chemicals and solvents, particularly those containing high concentrations of caustic soda or bleach. If spills occur, wipe them up immediately with water. To protect the surface, avoid using aggressive cleaning products and always follow the manufacturer’s care instructions.

No, Solid Surface does not require sealing. Since it is non-porous, it naturally resists staining and moisture penetration. However, regular cleaning with gentle cleaners is recommended to maintain its appearance.

Solid Surface benchtops are easy to clean. Simply wipe them down with a soft cloth, warm water, and a mild detergent. For stubborn stains, use a non-abrasive cleaner or a paste made from baking soda and water. Avoid using harsh abrasive pads that may scratch the surface.

Solid surface can be scratched by abrasive objects or when used as a cutting surface. Darker colors tend to show scratches more clearly than lighter ones. However, one of the benefits of solid surface is that it can be resurfaced, so scratches can be repaired or buffed out.

Yes, solid surface benchtops can be altered even years after installation. They are highly customizable, and professionals can resize, modify, or replace sections if needed. However, there are some limitations, such as the need to match the material batch for consistency. Please send us the details of what you need, and we’ll be happy to assist you.

Solid Surface is highly durable, but it can develop cracks if subjected to extreme stress, impact, or sharp objects. However, cracks are rare and can often be repaired by professional technicians.

Yes, cracked solid surface benchtops can be repaired. The repair process typically involves routing and filling the crack, followed by sanding the area smooth. Professional repair is recommended for the best results. The repair will be less noticeable if the solid surface used for the repair is batch-matched to the original benchtop. This is why Thermoform Fabricators provide customers with a ‘chopping board’ sized piece of material from the same sheets used for the original project.

Yes, solid surface materials can fade over time with prolonged exposure to UV radiation, especially in outdoor applications. Darker colours are more prone to fading. However, since the fading typically occurs only in the top layer of the material, a re-sanding can restore the colour and bring back the surface’s original appearance.

At Thermoform Fabricators, we typically use miter joints for waterfall legs and external corner edges. For benchtop edges, we usually join the pieces using a rebate-routered method. This method provides additional surface area for the adhesive, making the joint stronger. It also ensures a more complete bond, reducing the chance of the glue not fully filling the joint and minimizing the risk of the edge shifting during the glue-up process.

Absolutely! Due to its non-porous and seamless nature, solid surface is an excellent choice for shower and bathroom walls. While a silicone joint is still recommended in the corners, you can achieve a fully seamless look by adding cove to the corners. One of the key benefits is that, unlike traditional tiles, there’s no grout to clean, making maintenance much easier.

Yes, Solid Surface can be used for flooring, but there are some considerations. Unlike tiled floors, where grout provides grip and slip resistance, solid surface can be slippery. To improve traction, it’s recommended to sand the floor to a rougher finish. However, this textured surface may also trap more dirt.

Solid Surface material can typically span up to 600mm without additional support. For wider spans, a substrate or support framework is recommended to prevent sagging or damage over time.

A 12mm solid surface can typically have an overhang of up to 150mm. However, by adding 18mm or 25mm MDF, the overhang can be extended to 300mm. If a larger overhang is required, we recommend using a steel frame for support or installing brackets underneath the countertop to ensure stability.

At Thermoform, we primarily use white MR (moisture-resistant) MDF (medium-density fiberboard) for most applications, as the white melamine provides a clean underside to the solid surface. For external applications, aluminium or steel tubing is used, in line with many fabrication guidelines. Additionally, form plywood can be used depending on the client’s specific requirements. Particle board is only used when provided by the client, typically for applications like reception counters.

Yes, holes can be drilled into solid surface with care. It’s important to use a sharp hole saw or drill bit and maintain a slow drilling speed to minimize heat build-up during the process. A router can also be used to create holes. However, note that you should never screw directly into the solid surface. Instead, create a clearance hole and screw into the supporting structure beneath. Additionally, a jigsaw should never be used on solid surface, as it can cause damage.

No, you should never screw a threaded fastener directly into solid surface, as this can cause cracking and permanent damage. If screws are necessary, a metal or plastic insert must be glued in place to provide a secure threading point. Additionally, if screwing into the substrate from the underside, make sure the screw length is appropriate and does not penetrate the solid surface. Keep in mind that solid surface is typically 12mm thick.

No, you should never attempt to hammer a Nail into Solid Surface, this will damage your Solid Surface.

Yes, solid surface can be cut with a circular or table saw, and these are commonly used by professional fabricators. However, it is crucial to use the proper blade, as specified in the fabrication manual.

While it may seem like a straightforward process, fabricating solid surface benchtops requires skill and experience that takes years to master. The warranties on solid surface products are only valid when the material is fabricated by accredited professionals. For this reason, we do not sell sheets directly to the public. To ensure the best results and long-lasting durability, we recommend working with Thermoform, where our experienced fabricators can help bring your vision to life with precision and care.

Sorry, we are not currently aware of any reputable businesses selling solid surface directly to the public. However, some suppliers may sell to cabinetmakers or professionals with solid surface experience.

Solid Surface is a man-made material composed of a combination of acrylic resins, and natural minerals. The result is a durable, non-porous, and seamless surface material suitable for countertops, sinks, and other surfaces.

Unlike granite or quartz, Solid Surface is seamless and non-porous, making it easier to clean and maintain. While granite and quartz are more heat-resistant, Solid Surface offers more flexibility for custom designs and is easier to repair if damaged.

While Solid Surface is relatively resistant to scratches and chips, it is not completely impervious to damage. Avoid using sharp objects directly on the surface to keep it looking its best.

While solid surface can scratch, chipping is less common as it requires significant force. To maintain its appearance, it’s best to avoid using sharp objects directly on the surface. In the event of damage, repairs are possible to restore the material.

Solid Surface is available in over 300 colours from the four main brands we work with, along with additional options from lesser-known brands. For a full list of available colours, please visit our products page.

To maintain the shine of your Solid Surface benchtop, regularly clean it with mild soap and water, then dry it with a soft cloth. Avoid abrasive cleaners, as they can scratch or dull the surface. For full care and maintenance guidelines, please download the information from our products page.

Solid Surface is made from natural minerals and resins, and many products are designed to be recyclable. However, the environmental impact varies depending on the manufacturing process and materials used. At Thermoform, we strive to minimise waste during production and work with clients at the end of their benchtop’s life to find it a new home whenever possible.

Yes, Solid Surface is commonly used to create seamless sinks. These sinks can be moulded directly into the countertop for a sleek, continuous look without seams, making it easy to clean.

Solid Surface is resistant to most household and laboratory chemicals, but it is important to follow proper care instructions to avoid damage from harsh chemicals. Always clean spills promptly to prevent any potential damage.

You can request a quote by emailing your project details to info@thermoform.com.au. If you have additional details you'd like to discuss, feel free to call us at (07) 3892 2055.

Yes, Solid Surface can be thermoformed—a heating process that allows it to be bent or moulded into custom shapes. This makes it an excellent choice for curved or uniquely designed benchtops, sinks, and other surfaces.

To cut Solid Surface, you’ll need specialized tools such as a circular saw with a fine-toothed blade, CNC's, Routers or Trimmers. We recommend these tasks are left to professional Solid Surface fabricators to achieve precise cuts and clean edges.

Yes, Solid Surface is frequently used in commercial settings, such as offices, restaurants, hospitals, and schools, and labs due to its durability, ease of cleaning, and non-porous surface.

Yes, Solid Surface is highly durable and can withstand high traffic areas. However, like all materials, proper care and maintenance will help maintain its appearance over time.

Solid Surface is a popular choice for table tops due to its smooth, durable surface. It can be customized in shape and colour and is resistant to stains, making it perfect for both residential and commercial use.

Yes, Solid Surface is highly resistant to mould and mildew due to its non-porous nature. It does not provide a surface for bacteria or mould to grow, making it an ideal material for bathrooms and kitchens.

Solid Surface is a type of Acrylic-based material but is made with additional minerals for added strength and durability. It is typically more durable, has a higher resistance to wear, and can be seamlessly joined.

While Solid Surface is hygienic and durable, it is not recommended for use as a cutting board. Cutting directly on the surface can cause damage and will also dull your knives. Always use a separate cutting board to protect your benchtop.

Yes, Solid Surface can be polished. We recommend a semi-gloss finish for kitchen areas due to higher usage, while a polished finish is suitable for bathrooms. Over time, the surface will develop a natural lustre depending on how it is cleaned and maintained.

Yes, Solid Surface can sometimes be installed over existing countertops, depending on the condition of the current surface and installation requirements. However, if the existing countertop can be removed, this is generally preferred for the best results.

While Solid Surface is low maintenance, it is still important to clean it regularly to maintain its appearance. Avoid using harsh chemicals or abrasive pads that could damage the surface.

Yes, Solid Surface is commonly used in hospitals and medical environments because it is non-porous, easy to clean and resists bacteria and mould growth.

Yes, Solid Surface is an excellent material for bars and restaurant countertops. It offers durability, ease of maintenance, and a sleek, professional appearance.

Solid Surface is considered sustainable because it is made from natural minerals and resins, which can be recycled. Many manufacturers offer programs for recycling used or damaged pieces. Additionally, Solid Surface products are long-lasting, reducing the need for frequent replacements.

Solid Surface offers several benefits over natural stone, including greater flexibility for custom designs and the ability to create seamless joints. It is non-porous, easier to maintain, and repairable, providing a more consistent appearance. In contrast, natural stone can stain, requires regular sealing, and tends to be more inconsistent in both texture and colour.

Hard water stains can be cleaned using a vinegar solution or a non-abrasive cleaner. Simply apply the solution, let it sit for a few minutes, and wipe it clean with a soft cloth.

Yes, Solid Surface can be installed as a seamless backsplash. We use a cove detail between the horizontal surface and the vertical, which involves a third piece of material to create a smooth transition. This eliminates the need for grout lines, providing a sleek, easy-to-clean surface that's perfect for kitchens and bathrooms.

Yes, Solid Surface can be refinished to restore its original finish.

Acrylic-based Solid Surface is the preferred option due to its superior durability, offering better resistance to heat, impact, and scratching. It maintains its appearance over time and is ideal for high-use areas. While polyester-based Solid Surface is more cost-effective, it is more prone to scratching and may yellow over time.

Yes, solid surface can be used for shower trays, but there are some considerations. Unlike tiled floors, where grout provides grip and slip resistance, solid surface can be slippery. To improve traction, it’s recommended to sand the floor to a rougher finish. However, this textured surface may also trap more dirt.

Solid Surface performs well in humid environments due to its non-porous nature. It doesn’t absorb moisture, which prevents the growth of bacteria and mould, making it ideal for bathrooms, kitchens, and other moist areas.

Yes, Solid Surface can have integrated drain boards. If you're using an undermounted sink, we can router a variety of standard drain groove designs or create custom ones to suit your needs. When requesting a quote for your project, be sure to mention your interest in an integrated drain board and send an image if you have a specific design in mind.

Yes, custom designs or logos can be intergrate in to Solid Surface. Logos can be routed into the face of the material, Alternatively the back, allowing for backlighting to highlight the logo while keeping the surface easy to clean. We can also inlay different coloured Solid Surface materials to create the logo. If you're interested in a custom logo, please provide it in one of the following formats: clean DXF (no additional lines), EPS, AI (CS4 or lower), or CDR (X5 or lower).

Solid Surface is an excellent choice for schools and universities due to its durability, ease of cleaning, and hygienic qualities. It’s often used in Lab classrooms, cafeterias, and bathrooms.

Solid Surface is resistant to most household and laboratory chemicals, but it is important to follow proper care instructions to avoid damage from harsh chemicals. Always clean spills promptly to prevent any potential damage.

No, Solid Surface is non-porous and stain-resistant, meaning food and liquids typically won’t stain the material. However, it’s still important to clean up spills quickly to prevent any long-term discoloration.

Solid Surface can handle mild acidic or alkaline substances. However, it's best to avoid prolonged exposure to harsh chemicals or strong acids, as they can damage the surface.

Yes, Solid Surface is often used in medical settings due to its non-porous, easy-to-clean surface. It resists bacteria and germs, making it a hygienic choice for medical countertops and other areas.

Solid Surface offers a hygienic, non-porous, and easy-to-maintain surface, making it ideal for commercial kitchens. It resists bacteria growth and can be easily cleaned, making it a popular choice for food prep areas.

Yes, Solid Surface can be used in wet rooms or large shower wall areas. Its non-porous, smooth surface makes it easy to clean and resistant to water damage.

Yes, Solid Surface can be used in steam rooms, but allowances need to be made to ensure there is enough space for the material to expand as the room heats up. Please note that steam rooms are not covered under warranty.

Solid Surface more durable than laminate. It is non-porous, highly resistant to damage, and can be seamlessly joined for a smooth, continuous appearance. Laminate, in contrast, is more prone to peeling, and because the colour is only on the surface, any deep scratches will be highly visible.

While the initial cost of Solid Surface may be similar to that of granite or quartz, it is more cost-effective in the long run. Solid Surface requires less maintenance, is easier to repair if damaged, and can be refinished if scratched, reducing the need for costly repairs or replacements over time.

The main downside of Solid Surface is that it will scratch (similar to stainless steel) and is sensitive to high heat. Prolonged exposure to hot objects can damage the surface. Additionally, it may scratch more easily than granite or quartz if not properly looked after.

Yes, Solid Surface is suitable for lab workbenches and is commonly used in the production of laboratory sinks however,

Yes, Solid Surface can be used to create custom furniture pieces such as tables, desks, and shelves. Its flexibility in design and ability to be thermoformed makes it ideal for unique furniture applications.

Solid Surface is highly resistant to pet stains and damage. Its non-porous surface prevents liquids from penetrating, making it easy to clean up pet-related messes quickly.

Solid Surface can be used outdoors but some darker colours will be more prone to fading from UV radiation. Please note however, since the fading typically occurs only in the top layer of the material, a re-sanding can restore the colour and bring back the surface’s original appearance.

Unfortunately, Solid Surface does not have a formal recycling system in Australia. However, there are several options for disposal:

Repurposing: Your existing top can be remanufactured into other items that better suit your current needs.
Selling or Donating: You can sell the top or give it away so someone else can reuse it.
Thermoform Collection Service: We offer a pickup service for pre-removed tops at a cost of $198. These tops are placed in our offcut bin, where the material is available for free to the general public for crafting projects.

Yes, Solid Surface is recyclable. Many brands offer materials that contain recycled content, primarily using waste from the manufacturing process. However, full-cycle recycling systems are not yet in operation. Manufacturers are actively exploring sustainable recycling solutions for the future. For disposal options, see "How should I dispose of Solid Surface if it's no longer needed?"

Solid Surface is resistant to oils and grease.

Yes, Solid Surface is highly versatile and can be thermoformed to create custom shapes, including curves and angles. This allows for unique, tailored designs in countertops, sinks, and other applications.

If you can’t find a sink you like, Thermoform Fabricators can create a custom-made Solid Surface sink to suit your needs. Simply send your design plans to info@thermoform.com.au for a quote. Please note that custom sinks start at $2,200.

A washplane vanity is a flat surface (plane) that directs water to a slit drain, allowing it to flow to the waste. It is commonly used in commercial spaces for its clean and modern design.