Acrylic solid surface materials are versatile, durable, and stylish, making them an excellent choice for a wide range of applications, from kitchen countertops to commercial spaces like airports and laboratories. At Kstone, with 16 years of experience in manufacturing and custom processing, we specialize in creating high-quality acrylic solid surface products. In this blog, we will walk you through the main steps involved in processing these materials, including cutting, joining, sanding, modeling, and bending.

Step 1: Cutting the Acrylic Solid Surface

Cut sheet to required dimensions using circular saw with 80-100 tooth fine blade

Cut sink and cooktop openings using jigsaw with bi-metal blade; drill pilot hole first

Route edges to desired profile (bullnose, bevel, etc.) using router with bearing-guided bit

Sand cut edges progressively: 120-grit → 220-grit → 400-grit

Step 2: Joining the Pieces

Once the sheets are cut to size, the next step is to join the pieces together. Acrylic solid surfaces are known for their seamless joints, which can be achieved using a high-quality acrylic bonding adhesive. We apply a precise amount of bonding glue to ensure a strong, invisible seam that maintains the sleek, modern appearance of the surface.

Step 3: Sanding and Polishing

• Dry sanding (remove tool marks):

  • Start with 100-grit. Sand the entire top, edge, and seams until all saw/route marks are gone.

  • Switch to 120-grit. Sand across the previous sanding direction to remove 100-grit scratches.

  • Switch to 180-grit.

  • Switch to 220-grit.

• Wet sanding (polish):

  • Pad must stay wet. Rinse frequently.

  • 320-grit.

  • 400-grit.

  • 500-grit (optional for matte finish).

  • 600-grit (optional for semi-gloss)

Step 4: Surface finishing

• Dry sand with 120-grit to remove tool marks

• Progress to 220-grit for smoothing

• Finish with 400-grit wet sanding for polished appearance

• Buff with solid surface polish

Step 5: Installation

Ensure cabinets are level; shim if necessary

Place countertop on cabinet base

Drill pilot holes through cabinet rails into underside of countertop

Secure with 1-inch wood screws, spaced 12-16 inches apart

Seal around sink and cooktop cutouts with silicone caulk

solid surface

solid surface fabricaton

solid surface countertop