Key Responsibilities
The Solid Surface Fabricator is responsible for transforming acrylic solid surface materials (such as Corian) into high-end custom countertops. This role demands thermal manipulation, seamless bonding techniques, and precision multi-stage finishing to meet demanding quality and high standards.
Thermoforming & Advanced Shaping
Thermal Management: Operate heating plate to evenly heat acrylic-based solid surfaces to precise target temperatures (150°C-175°C), ensuring maximum material elasticity while strictly avoiding blistering, whitening, or scorching.
Moulds & Jigs: Design, construct, and modify custom moulds using plywood from CAD drawings.
Stress Relieving: Monitor and control the cooling cycle under tension to correctly set the material, eliminating internal memory and preventing post-release spring-back or warping.
Seamless Seams & Bonding
Adhesive: Select, mix, and apply batch-matched, two-part acrylic or polyester adhesives to eliminate visible seam lines ("glue lines") and achieve a single-piece appearance.
Clamping & Alignment: Deploy Spring clamps to apply uniform pressure, extracting excess adhesive and air bubbles without starving the joint.
Infiltration Prevention: Fabricate watertight, hygienic coved upstands, splashbacks, and drip-grooves to eliminate moisture or bacterial accumulation points.
Precision Sanding & Finishing
Progressive Gritting: Use multi-stage sanding sequences using random orbital sanders (ranging from 80/120 grit up to 400+ grit or micro-abrasives) without skipping steps to avoid trapping deep surface scratches.
Sheen Level: Deliver tailored finishes to match client and design specifications:
Matte/Satin: Progress to mid-range abrasives followed by non-woven web pads for a soft, uniform, low sheen look.
High-Gloss: Utilise ultra-fine finishing discs, wool bonnets, and specialised polishing or buffing compounds to achieve a flawless mirror-like finish.
Optical Clarity: Maintain consistent tool speed, crosshatch movement patterns, and downward pressure to prevent "dipping," shadowing, or lensing effects over seams and large planes.
Dust Extraction Management: Operate dust extraction systems coupled directly to sanding equipment to maintain a clean workshop environment and prevent disc clogging.
Quality Assurance
Conduct regular in-process inspections to ensure all products meet the standard drawing and tolerances.
Inspect finished parts for surface scratches.
Segregate and log formally all non-conforming materials.
Record quality checks in accordance with company procedures.
Report quality concerns promptly and support corrective actions where required.
Develop a high level of attention to detail and commitment to right-first-time manufacturing.
Additional Duties
Undertake any other reasonable duties as required by management, appropriate with the nature, level and responsibilities of the role.
Demonstrate flexibility in supporting wider operational and business requirements as necessary.
This job description is intended to outline the main duties and responsibilities of the role and is not exhaustive. Duties may be reviewed and amended from time to time to reflect changing business needs, following appropriate consultation where required.
Previous experience in solid surface fabrication is desirable but not essential. We welcome applications from people with practical aptitude, strong attention to detail and a willingness to learn. Experience in joinery, cabinetmaking, furniture manufacture or a similar workshop environment would be advantageous. Applicants should have basic numeracy skills, be able to follow instructions accurately and demonstrate a reliable, safety-conscious approach to work. Role-specific training will be provided, with duties undertaken in line with training and demonstrated competence.
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