Design Smarter, Not Harder
By designing with the material — not against it — you get:
- Cleaner installations
- Lower fabrication costs
- Fewer on-site issues
- Longer-lasting projects
Designing In Solid Surface:
This guide is meant to help designers, engineers, and others get the best results when working with solid surface materials. By following a few proven techniques, you can save time, reduce waste, and ensure beautiful, durable installations.
Even experienced professionals sometimes run into challenges with solid surface, it’s a unique material with its own best practices. This resource highlights a few common design pitfalls and simple ways to avoid them, making the fabrication and installation process smoother for everyone.
The goal is to support great project outcomes through smarter planning and better communication between the designer and our fabrication team.
Thermoform assumes no responsibility for results obtained or damage incurred from the use of this information.
All Applications
Standard Thickness: 12mm is the standard thickness we use for fabrication. A very limited range of colours are available in 6mm and 19mm thick Solid Surface and these thicknesses tend to be less cost effective.
Standard Sheet size: 3660 x 760 for most sheets (We love clean numbers, so we work to 3650 x 750. It also gives the fabricator a little breathing room to trim and square things up.)
Joins are seamless: Joints in solid surface are chemically bonded and then sanded flush, resulting in nearly invisible seams, especially in solid or fine-patterned colours.
Veined or marbled colours will show seam lines, even though the join is physically seamless. Vein patterns cannot be matched across joins because each sheet is unique but veins can often be match end to end depending on brands /colour of sheet. This variation is not a flaw, but should be anticipated and clearly communicated to clients. If placement is of concern ask for join locations to be advised.
Colour Variation: Even with the same colour name, sheet appearance can vary slightly between production batches.
Expansion allowance: 1mm per metre of material between fixed elements like walls or cabinetry.
Finish: Our standard finish is semi-gloss, smooth enough to feel luxurious, but not so shiny it shows every mark. Over time, your benchtop will develop a gentle patina based on how it’s used. Solid surface can be refreshed like new, usually around the 5–10 year mark. (let’s be honest) It’s normally done just before the house goes on the market and everything needs to look ‘accidentally perfect’.
Reparability: Scratches and cracks can be sanded or patched similarly to how the surfaces are initially joined, resulting in an almost invisible repair. The most common repair requests are made when pesky cooktop manufacturers refuse to make cooktops the same size as their original units. We often enlarge or reduce cut outs to accommodate the new cooktop.
non-porous surface: it resists bacteria, stains, moisture and mold.
Seamless: This means you can continue your tops up into the backsplash(cove join), do seamless sink integrations or create large waterfall at the end of counters.
How to Specify - Documentation
If you have chosen a brand but not a colour within that brand, clearly mark on all documentation: ‘brand name‘ and ‘colour to be advised‘.
When your colour has been decided, clearly mark on all documentation: ‘brand name‘ and ‘the name of the colour‘.
Note: Please be aware that some brands may use the same or similar colour names, but the actual colours and their pricing can vary significantly. If you would like to view samples, they are available in our Showroom.
Alternatively, as much as three samples can be posted out to you at your request. Please email info@thermoform.com.au
If you are an Architect, Designer, Cabinetmaker or any other business that requires a full sample box, please phone our office for arrangements to be made.
Designing With 12mm Only Solid Surface
Since solid surface sheets are 12mm thick by default, starting with 12mm keeps fabrication simple and cost-effective. Designing within the material’s strengths (as outlined below)
offers:
- A clean, minimal profile
- Strength and durability for most residential and commercial uses
- The best balance of material cost and performance
Design Considerations
Max overhang: 150 mm.
Support for top: 600 centers – support needs to be provided within the cabinetry at 600 centers. This can also be solved with a shadow line detail that spans the length of the cabinets or if the cabinets are built with full tops or with additional internal rails.
Join locations and strapping: standard sheet sizes are 3660 x 760 If your top is longer then 3660 or wider that 760, we can join seamless to the next sheet, but most solid surface brands require strapping to be placed under the solid surface to strengthen the join for warranty.
Waterfall-Gabel end: Note that the back of a sheet is often not the same pattern as the front to the sheet Please ensure you have viewed the back of the sample to ensure this is acceptable.
Common Pitfalls and How to Avoid Them
300mm Overhangs: These will require extra support – Consider designing with an “Up to 50 mm edge” or add decorative brackets spaced at 600 centers to support the top. Consider integrating support features into cabinetry design early, rather than treating them as afterthoughts.
Large Sink Cabinets: Most sink cabinets are wider than 600mm. Strong supports need to be placed at the front & back of the top. The support should be able to hold 135 kg without Flexing more than 3mm.
No support over Washing Machines & Dryers: Ensure there is room for Steel, Aluminium or other support structures to span above appliances. Alternatively, you can include gables or side panels into your design, either side of your Appliance cavities to provide the necessary support for your Benchtops.
How to Specify - Documentation
Ensure that edges are marked as 12mm in your drawings. If edges are unmarked, it can be difficult to determine the exact thickness, so we will default to allowing for an up to 50mm edge. Zoomed-in details of edge profiles are also valuable. Please also ensure your drawing includes the supporting structure, especially when overhangs or spans over 600mm are involved.
Designing With up to 50mm Edges
At Thermoform, any edge thicker than 12mm and up to 50mm is quoted as a “50mm edge”. To achieve this look, a separate strip of solid surface is bonded into a rebate and then sanded flush. This creates the appearance of a thicker top.
To support the benchtop, we use a ladder style substrate system with white MDF as our standard.
Standard Edge Build-Ups
| Finished Edge | Solid Surface | MDF Substrate | Allowance for Silicone |
|---|---|---|---|
| 25mm | 12mm | 12mm | 1mm |
| 31mm | 12mm | 18mm | 1mm |
| 38mm | 12mm | 25mm | 1mm |
| 50mm | 12mm | 25mm + 12mm | 1mm |
Design Tip
Edges up to 25mm follow the same design principles as 12mm-only tops (see above).
Design Considerations
Max overhang: 300 mm.
Support for top: The Substrate will offer support in most cases, large open spans still require additional Steel or Aluminium support.
Join locations and strapping: Joins in some products are reinforced with solid surface strapping which is concealed within the substrate.
Waterfall-Gabel end: Waterfall legs can increase material use and cost, especially when paired with overhangs. We include a 150mm return strip on the inside of the gable (where the kickboard runs behind). When a waterfall leg meets a top with an overhang, additional material is required to wrap the internal side to maintain visual continuity.
Common Pitfalls and How to Avoid Them
450mm overhangs: These will need to be supported. Add decorative brackets at 600 centers to support the top or design with Steel framing. Consider integrating support features into cabinetry design early, rather than treating them as afterthoughts.
Mistaking Edge Thickness for Solid Material: This is very common because solid surface joins are not noticeable. A 50mm edge doesn’t mean the entire top is 50mm thick. It’s a visual build-up on the front, sides, and returns — the rest is still a 12mm sheet with a substrate underneath.
The underside of overhangs in solid surface: Because the substrate also supports the overhang, it’s not standard for the underside to be clad in solid surface. This is possible, but it typically requires additional support, such as aluminium or steel rods, placed between the two layers.
How to Specify - Documentation
Ensure edges are marked with measurements in your drawings. Zoomed-in details of edge profiles are also valuable. Drawing should includes the supporting structure.
BBQ & Outdoor Tops
Design Considerations
We’ve found that using solid surface outdoors solves a lot of the problems that come with other materials, short of going for a full stainless steel top. Because it’s non-porous, it won’t absorb spills or get damaged by a bit of rain, and there are no grout lines or open seams to worry about either. That makes it much easier to keep clean.
Heat Exposure: BBQ appliances generate intense heat. To avoid thermal damage:
Allow minimum 50mm clearance between the solid surface and BBQ heat shields. Ensure the appliance is correctly insulated and has built-in ventilation.
Never allow direct contact between the BBQ body and the solid surface benchtop.
UV-Stable Colours: Choose from colours specifically rated for UV resistance and outdoor exposure (often limited to whites and light neutrals). Each brand has it own list of each is available via the drop-down menu below
Substrate and Support Requirements: We use aluminium tubing for all external applications. MDF should not be used. Outdoor environments demand extra care in structural support.
Edge Thickness : Material is 12mm (see above it you want to work with 12mm only)
| Finished Edge | Solid Surface | Aluminium | Allowance for Silicone |
|---|---|---|---|
| 25.7mm | 12mm | 12.7mm | 1mm |
| 29mm | 12mm | 16mm | 1mm |
| 38mm | 12mm | 25mm | 1mm |
| 63mm | 12mm | 50mm | 1mm |
Common Pitfalls and How to Avoid Them
Not considering what type of BBQ will be used:
Whether you’re using a top-mount or drop-in BBQ, each style has different design implications. The choice will affect how the benchtop is cut, how heat is managed, and the style of protective surround required around the appliance.
How to Specify - Documentation
Ensure that it is clear that top will be in an outdoor location. Label the BBQ location. Add descriptions of what type of surround will be used.
Working with Veins
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Design Considerations
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Common Pitfalls and How to Avoid Them
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How to Specify - Documentation
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Obtaining a Quote
Email to: Info@thermoform.com.au
The more details you provide, the easier and more accurate the quote can be. We quote projects based on the number of sheets required and the number of hours it will take to complete the job.
Each brand of solid surface will have different price ranges for different colours. The most affordable colour is normally white or an off-white, followed by mid-range and premium colour range. If you have not chosen a colour, we will do a three colour/range base quote.
Alternatively, if you are deciding between three colours or less we will quote each for your convenience.
Please see our colour pages or visit us in person at 5 Dexter Street, Moorooka QLD 4105 to look at colour samples.
Your plan should show a basic layout of the tops with lengths and widths of each piece.
Please include the following details:
- Edge thickness and style
- Sink (drop-in or undermount)
- Cooktop (dropping, upright or recessed)
- Splashback (height, coved or drop on)
- Waterfall (gable ends) distance from the floor