How Acrylic Solid Surface Sheets Are Made – Full Production Process

Acrylic solid surface sheets are widely used in countertops, wall cladding, furniture, and decorative applications due to their durability, seamless appearance, and design flexibility. In this guide, we’ll explore the step-by-step manufacturing process of acrylic solid surface sheets, from raw materials to finished products.

1. Raw Material Preparation

The production of acrylic solid surface sheets begins with high-quality raw materials:  

- Acrylic Resin (PMMA): Polymethyl methacrylate provides transparency, UV resistance, and weatherability.  

- Mineral Fillers: Aluminum trihydrate (ATH) is commonly used to enhance strength, fire resistance, and opacity.  

- Pigments & Additives: Colorants, stabilizers, and curing agents are added for aesthetics and performance.  

These materials are precisely weighed and mixed in an automated batching system to ensure consistency.  

2. Mixing & Homogenization

The raw materials are loaded into a high-speed mixer to create a uniform slurry. The mixture must be free of air bubbles and lumps to ensure a smooth, defect-free surface. Vacuum degassing may be applied to remove trapped air.  

3. Casting Process

The liquid mixture is poured into:  

- Flat Casting Molds: Made of stainless steel or glass for smooth surfaces.  

- Textured Molds: If a patterned finish is desired.  

The molds are carefully leveled to ensure even thickness.

4. Polymerization (Baking/Curing)

The filled molds are transferred to a curing oven, where they undergo controlled heating:  

- Gel Phase (50-80°C): Initial hardening to prevent deformation.  

- Full Cure (80-120°C): Complete polymerization for maximum strength.  

This process takes several hours, depending on thickness.  

5. Demolding & Cooling

After curing, the sheets are removed from the molds and cooled gradually to prevent warping. The edges are trimmed to achieve precise dimensions.  

6. Surface Finishing

The sheets undergo several finishing steps:  

- Sanding: Automated sanders smooth the surface (from coarse to fine grit).  

- Polishing: Buffing wheels or chemical polishing create a high-gloss or matte finish.  

- Quality Inspection: Visual and machine checks for defects like bubbles or scratches.  

7. Cutting & Fabrication

Sheets are cut into standard sizes (e.g., 2440x760mm) or custom shapes using:  

- CNC Routers:For precise cutting, sink cutouts, and edge profiling.  

- Waterjet Cutters:For intricate designs without thermal damage.

8. Packaging & Shipping

Finished sheets are wrapped in protective film, packed with foam or cardboard, and shipped to distributors or fabricators.  

Conclusion

The production of acrylic solid surface sheets involves precise material selection, advanced casting, and meticulous finishing to ensure durability and aesthetics. This process allows for endless design possibilities, making it a preferred choice for modern interiors.  

You are invited to watch the production video of our factory workshop.

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