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Having been in the European solid surface business since 1985, I have seen a lot of changes. In the beginning there was only one brand with three color options. The material was ¾ in. with basic quality issues, and was a very expensive product. Today at least a dozen internationally and well-known suppliers and brands are available with more than 100 colors, textures and sizes. Better and more consistent quality, along with an affordable product and image, is also available.
Lately in our industry, we have been experiencing new challenges: quartz products taking major shares from the solid surface countertop market or the crises from the U.S. housing market with global influence into the global finance systems. Both of the latest developments have major influences on the solid surface fabricator — the countertop business is decreasing, resulting in less turnover, less profit and in some cases laying off people and shop closings.
One answer to the rapid changes is developing new markets and looking for new business opportunities, followed by slightly changing the company's profile. Thermoforming is one of the new opportunities for a solid surface fabricator to look into. It is a new market that lends personality to solid surface, and requires only a small investment to begin.
A New Market
Right now, most of us are only fabricating and installing countertops and are therefore dependent on the residential market. Thermoforming is following a new strategic path into the architectural/design community and commercial market. Following this design route is one solution of becoming independent of the latest developments in the U.S. housing market.
Thermoforming is advantageous and unique for solid surface and can help minimize the competition. At the same time however, thermoforming requires investment, training, experience and a budget including marketing/sales for the additional and different market (calling on architects and designers). Not all your colleagues will take this path.
There are a lot of other "flat" countertop materials in the market, e.g., laminate, granite, wood, tile, stainless steel, etc., but no other material can be thermoformed to this extent or even 3-dimensionally. Over the past 40 years solid surface has been sold and used as flat sheet. The hygienic aspects, as well as the durability, were key arguments to sell — but a lot of other products are similar or became similar through R&D over time.
How do we differentiate between products? What is the key, the personality and the uniqueness of solid surface material? I see it in translucency and thermoformability.
In history, solid surface fabrication technology has been driven from Europe. Half-inch fabrication technology has already been used since the mid-'80s, 2-D thermoforming technology since the beginning of the '90s and 3-D thermoforming technology since 1995, beginning with thermoforming bowls. More recently we've seen 3-D thermoforming technology in major design projects like in the Hotel Puerta America, Madrid, Spain, or the LEONARDO project in Bad Driburg, Germany.
To get started is easy — thermoforming just needs some creativity, an investor and especially the fabricators. I would recommend beginning with 2-D thermoforming for skirts of vanities, vertical panels of counters or columns, or similar shaped products.
You need a basic understanding of solid surface material as well as basic fabrication techniques to build the required templates or molds for thermoforming. Education and further details on 2-D thermoforming are public today and have been provided through many outlets, especially from ISSFA (www.ISSFA.org) and its training programs, as well as from every major solid surface manufacturer's company manuals and within their in-house training programs.
Moving on to 3-D thermoforming will require a substantial amount of experience in 2-D thermoforming first, followed by investing in people, "know how" and specialized equipment. Thermoforming in 3-D requires another level of experience and investment, and I would recommend that from the beginning, and possibly a long time, you consider cooperating with a specialist.
Little Investment
The only thing you will need to get started, in addition to your normal solid surface shop equipment, is an oven. There are several types in the market. In Europe, companies primarily use the "platen oven," and through my experience it will give the best long-term results. Several suppliers for ovens are in the market and information can be gained through a number of sources, including this magazine, ISSFA and solid surface manufacturers.
As you become more experienced and create more jobs that use thermoforming, you might become interested in investing in some kind of vacuum press or platen press to further develop your capability and focus on thermoforming. The more involved you become in this niche, the more you will have to invest in specialists/engineers and further sophisticated equipment. However, it should lead to more business, also.
In thermoforming, I see discovery and creativity in the unique personality of solid surface. I see a great future in building this market beyond today's countertop business. I see a market opportunity that we are at the beginning of understanding and creating. There will be a lot of interesting ideas and there are many new developments coming up in the future to keep an eye on, like 3-D thermoforming machines.
About the author:
Martin Funck is partner and president of Rosskopf & Partner AG, a European leader in solid surface and quartz surface fabrication. He is a founding member of ISSFA and has served two terms on the board of directors. For more details and references to thermoforming projects, see the company's newly designed Web site www.rosskopf-partner.com.
author: By Martin Funck