What is thermoforming and what is it used for?

Key points of Solid Surface thermoforming

• • 1. Creation of complex 3D pieces: Solid Surface thermoforming allows the manufacture of three-dimensional components using heat, precision molds and vacuum or pressure.

• • 2. Continuous and stable surfaces: Produces seamless surfaces with high stability, resistance and repairability.

• • 3. Tailor-made solutions: Provides custom options for furniture, countertops, washbasins and cladding.

• • 4. Complete technical workflow: Indutec Solid integrates thermoforming, CNC machining and prototyping in a unified technical process.

• • 5. Advanced geometries: Allows small radii, smooth transitions and complex shapes for architecture, retail and contract projects.

• • 6. Technical benefits: Precise curvatures, integration of lighting or sensors, and compatibility with demanding environments.

• 7. Precision and stability: Thermoforming delivers consistent and stable three-dimensional results.

What is thermoforming?

Thermoforming —also called thermal forming— is an industrial process that uses controlled heat to bring a thermoplastic material to its elasticity point, then adapt it to a specific mold or structure. This allows shapes that would be impossible through traditional machining or flat assemblies.

In the case of Solid Surface, thermoforming is especially efficient because of:

• Its mineral-acrylic composition, which withstands high temperatures without deterioration.
• Its homogeneous behavior after cooling, with no internal stresses or deformation.
• Its capacity to achieve small bending radii while maintaining aesthetic and functional integrity.
• The possibility of producing complex pieces with no visible joints, ideal where hygiene or design continuity are priorities.

This process is used both for one-off projects and serial production where repetitive precision is essential.

Main materials used in thermoforming

Although many materials can be thermoformed, the most relevant in professional environments are:

Solid Surface (Krion, Corian, Avonite and others)

The material with the best thermal performance, highest stability and the finest surface finish. Enables precise curves and continuous surfaces.

> Here you can find more information about Solid Surface.

Technical plastics (PMMA, PETG, ABS)

Used in lightweight projects, signage or displays.

Thermoformable laminates

Suitable for curved surfaces in technical furniture or interior cladding.

Acrylic (Methacrylate)

High light transmission and excellent compatibility with backlighting or retail projects.

Solid Surface remains the reference when durability, resistance to humidity, chemicals and heavy traffic are required.

Thermoforming methods

The main methods used by specialized manufacturers are:

Vacuum forming

The heated sheet is placed over a mold and vacuum is applied so that the material exactly copies the geometry. Very useful for deep or pressed shapes.

Pressure forming

Ideal for pieces requiring high surface precision and excellent definition.

CNC-assisted forming

Pre-machining ensures constant thicknesses and defined radii, enabling more precise and uniform bending.

Manual forming with templates

Used for custom pieces, prototypes or very specific on-site adjustments.

The choice of method depends on thickness, required bending radius, tolerance and design complexity.

What is thermoforming used for?

Thermoforming is essential when a project requires:

• Curved or three-dimensional pieces with no visible joints.
• Technical furniture with high hygienic requirements.
• Continuous cladding for high-use spaces.
• Custom solutions for retail and contract seeking visual differentiation.
• Product design components where precision and finish are essential.

It is used for both functional parts and purely aesthetic elements.

Application in materials such as Solid Surface

Solid surface thermoforming offers a level of versatility very difficult to achieve with other materials. Its composition —a mineral blend with high-purity acrylic resins— responds predictably to heat, enabling the transformation of flat sheets into complex three-dimensional geometries without compromising technical performance.

When solid surface is heated uniformly within its optimal thermoforming range, the material gains enough flexibility to adapt to molds with great precision. Once cooled, it maintains the shape with full dimensional stability, with no irregular shrinkage or internal stresses.

At an operational level, thermoforming enables:

Dimensional stability

Solid Surface maintains the geometry obtained in the mold without later deformation. Essential for technical furniture, modular bars or integrated bathroom solutions.

Complete absence of porosity

After thermoforming, the material remains non-porous, preventing moisture absorption and facilitating hygiene in sensitive environments such as healthcare, hospitality, retail or heavy-use contract spaces.

Continuous finishes without irregularities

The surface can be professionally sanded to achieve matte, satin or polished finishes, resulting in a uniform surface highly valued in premium projects.

Repairability and adaptability

Even after installation, Solid Surface can be corrected, expanded or adjusted. This reduces risk during execution and extends product lifespan —important for interior designers, architects and product designers.

Common applications of thermoformed Solid Surface

The range of solutions is broad and adaptable across sectors. Highlights include:

Ventilated façades and architectural envelopes

They allow the creation of volumes, curved transitions and three-dimensional panels that bring identity to the project while providing resistance, durability and low maintenance.

Seamless curved countertops

Kitchen or bathroom surfaces can be executed with continuous curves, rounded edges and invisible joints, improving hygiene and ergonomics.

Monolithic integrated washbasins

Thermoforming enables bowls, fronts and surfaces in a single piece with no visible joints, commonly used in hotels, healthcare spaces and high-traffic bathrooms.

Wrap-around retail counters

Enables bars, desks and receptions with fluid lines, organic forms and custom geometries that strengthen brand identity.

Organic cladding for hotels, contract spaces or clinics

Thanks to its non-porous structure and excellent behavior in humid environments, thermoformed Solid Surface allows curved walls, niches, envelopes and backlit panels.

3D pieces for product design, prototypes or small series

Used to develop exact volumes, functional prototypes and small runs with precise geometries.

Discover the advantages of Solid Surface in architectural and design projects.

Thermoforming process step by step

Material preparation

The sheet is selected according to thickness, color, thermal behavior and technical viability.

Homogeneous heating

The material is placed in an industrial oven and gradually heated to its optimal elasticity point.

Forming on the mold

Once flexible, the sheet adapts to the selected mold using vacuum, pressure or a mixed system.

Structural cooling

The piece stabilizes while cooling uniformly, avoiding internal stresses or irregular shrinkage.

Finishing and assembly

Surfaces are sanded for a continuous finish. If joints are required, they are made invisible.

Advantages of thermoformed Solid Surface

Thermoformed Solid Surface opens a wide range of possibilities that go far beyond simply bending a material. For architects, interior designers, product designers and technical teams, it is a way to elevate design without construction risks.

In retail, contract, healthcare, hospitality or product design, thermoforming provides a competitive advantage: exclusive custom pieces with stable quality regardless of complexity.

Main advantages include:

• Exact curvatures with constant radii and controlled tolerances.
• No visible joints, essential for hygiene, aesthetics and maintenance.
• Repairable and durable surfaces, even in demanding environments.
• Complex 3D shapes impossible with wood or natural stone.
• Integration with lighting, sensors or functional elements.
• Compatibility with interiors, exteriors and humid environments.

These characteristics make it an ideal material for premium projects.

Thermoforming uses in decoration and furniture

Thermoforming takes design to a higher level, especially in spaces where form defines user experience.

Countertops, washbasins and bathroom furniture

Enables seamless integrated washbasins, curved shower trays, ergonomic countertops and humidity-resistant furniture.

Curved elements in kitchens or retail spaces

Thermoformed Solid Surface is used for:

• Wrap-around bars and counters.
• Fluid-shaped retail furniture.
• Cladding aligned with brand identity.
• Custom pieces for storefronts.

When a project requires precision, brand adaptation or a differentiated commercial experience, Solid Surface is a strategic ally.

Discover how we work with this material at Indutec Solid

Considering curved or custom solutions for a project?
The technical team at Indutec Solid offers design, feasibility, prototyping and manufacturing support, ensuring deadlines, precision and flawless finishes.
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If a project requires advanced geometries, visual continuity and a durable material that maintains its performance over time, solid surface thermoforming is the most versatile and reliable solution. Working with a specialized team is essential to ensuring results, timing and impeccable execution.