Cast polymer is an umbrella term used for Solid Surface, Cultured Marble, Cultured Granite, Cultured Onyx and Polymer Cast Products. As their names imply, have the look of genuine marble, granite or onyx.

The origin of “Cast Polymer” can be tracked back to over 40 years. Since that time, cast polymer manufacturing has grown rapidly worldwide, and is utilized for the efficient production of sanitary ware, as well as kitchen and bath applications for new home construction, multi-unit residential construction, remodeling, and for commercial applications.

Solid Surface has long been misunderstood as a rich man’s luxury.  This sentence can be refuted time and time again; Solid Surface is affordable to all.

Solid Surface is manufactured in full wall sizes, providing clean lines and minimal joints.  As it is non-porous it eliminates the health concern of mold, mildew and bacteria. There are unlimited color and design choices and the ultimate opportunity of making your own design, manufactured into the Solid Surface. It is possible that your color and design choices will change long before Solid Surface will need to be.

polymer

Some applications include: counter tops, vanities, shower bases, bathtubs, enclosure sets, fireplace surrounds, window sills, wall panels, floor tiles, toilets, moldings and much more.

Cast polymer products are man- made, chemically bonded, mineral filled, polymeric materials which are molded and hardened to a solid material in a variety of shapes that meet diverse design needs. The manufacturing process permits a range of uses almost impossible to achieve with quarried stone. Being stronger and less brittle than quarried marble and more durable than porcelain, cast polymer resists mildew and stains and bacteria are easily cleaned with non-abrasive cleaning agents (environmentally friendly products). The one-piece, seamless construction of cast polymer is easy to maintain and resistant to breakage. and, if for some unfortunate reason a consumer scratches the Solid Surface, a home owner, or technician visit the home and eliminate it altogether.

Today’s cast polymer products offer improved construction, top-notch materials, and superior quality control standards. The result permits a total kitchen and bath concept with products that last longer, look better – yet still allow freedom of colour and design-versatility at an affordable price.

The polymer casting process yields a rock hard, durable product which takes on the look and feel of the natural product. The benefits over natural material is its ability to be shaped by the use of molds to control its look, colour, texture and other properties.

Solid Surface looks very much like natural stone, imitating its surface patterns and colours, but up to four times tensile (stress) strength and unlike natural marble, will not stain easily. Natural marble is very porous and used primarily in flat surface applications whereas Solid Surface can be formed into virtually any shape or size depending on the form and shape of the mold.

Cultured Granite simulates natural granite surface patterns and colours, but once again, can be formed in any shape and design with up to four time tensile (stress) strength of natural granite.

Cultured Onyx features translucency allowing light to pass through. It simulates natural onyx surface patterns and colours.

Manufacturing Process

A homogenous mixing process of inert filler and unsaturated polyester resin produces a cast polyester product that can be used for decorative or industrial applications. This finished product has excellent mechanical and chemical properties.

  • Liquid Components
    • Unsaturated polyester resin, accelerator, inhibitor, and catalyst are blended together in proper ratios and formulations according to weight, volume, and atmospheric conditions
  • Solid Components
    • Inert fillers of particle size distributions and dryness characteristics are mixed into the liquid components creating what is referred to as the MATRIX compound. In addition one of several colour pigments are added to achieve the desired colour and pattern effect in the finished products.

 Mold Handling:

The Matrix is cast on to the surface of a previously prepared mold. This preparation includes surface cleaning, release agent treatment. Once the mold has been filled with Matrix, they are transported to a vibration area for a specific time period. From there, the molds are placed in a curing zone after which the finished product is taken out of the mold. Final products are inspected and finished accordingly.