Learn about Krion® and its thermoforming properties

Krion® Lux is a solid surface that redefines what it means to work with innovative materials. Its composition, based on high-quality minerals, and its properties give it exceptional strength and an aesthetic that allows it to adapt to all types of projects. However, in this blog post, we are going to take a closer look at one of its most outstanding properties: thermoforming. 

What will you discover in this article?

• Discover how thermoforming allows you to create curved surfaces and pieces for custom projects.
• You will learn the steps that professional installers must follow to carry out this process and adapt the material to the needs of each project.

What is thermoforming?

Thermoforming is a technique that allows solid materials to be moulded by applying heat and pressure. This process transforms solid surface sheets into curved and complex shapes, allowing for customised designs tailored to specific projects. It is a property that also makes it highly versatile compared to other materials, allowing it to be used in a wide range of applications and styles.

Thermoforming in Solid Surface

The thermoforming process consists of heating a sheet of material to a specific temperature, then moulding it with a mould and a vacuum press with a membrane.

This technique allows specific curvature radii to be obtained without altering the colour intensity of the Krion® LUX sheet, ensuring that the finished pieces retain all the properties of the material.

Proyecto: Artendeck

See at Porcelanosa Projects

Advantages of thermoforming solid surface

Thermoforming offers a number of advantages that make it ideal for a wide range of applications. Below, we explore the main strengths of this technique.

Adaptability to complex designs

This property allows for the creation of curved shapes and complex structures that would not be possible with other materials. This opens up a range of possibilities for creative and customised projects, perfectly adapting to the technical, aesthetic and functional needs of each space and project.

Krion® Lux Nebula Vanilla and Grigio

Maintenance of the aesthetics and properties of the material

One of the great advantages of thermoforming is that the process does not alter the colour intensity or properties of the material. Krion® LUX maintains its uniform appearance even after being moulded, ensuring a flawless finish.

Strength and durability

Thermoforming not only allows for greater design flexibility, but also maintains the high strength and durability that characterise this material. The surfaces remain as resistant to impact, scratches and stains as unmoulded sheets, ensuring a long service life for the material. 

Step-by-step thermoforming process

The thermoforming process is key to transforming Krion® LUX sheets into complex shapes tailored to the needs of each project. Below, we detail each step of the thermoforming process.

Before starting this process, it must be confirmed that the Krion® LUX reference colour to be used can be thermoformed to the radius specified for the project. This information can be confirmed by the transformation specialist who will carry out this work in the Krion® LUX transformation manuals.

Digitel Tower Project

See in Porcelanosa Projects

Step 1: Preparation of the material

Proper preparation of the material is crucial to achieving a successful end result. In this step, the edges and corners of the pieces are sanded to prevent damage to the vacuum membrane during the thermoforming process or breakage of the piece to be manufactured. In addition, the surface is checked to ensure that it is completely clean and free of impurities. Krion® sheets should be cut slightly larger than the final dimensions of the design to allow for shrinkage of the material during heating.

Step 2: Heating the material

Heating is a critical step, as the sheet must reach a precise and uniform temperature throughout its thickness in order to be moulded without compromising its properties.

Temperature and heating time are key to making Krion® LUX malleable.

The heating temperature is generally 160ºC, but it is possible to set lower values of 130º to 150ºC to mould simpler shapes with wider, more open radii.

The time required to heat the material depends on the characteristics of the oven to be used and the thickness of the Krion® LUX sheet. The most common ovens are the so-called ‘hot plate’ (double or single) and ‘convection’ or hot air circulation ovens. As a rough guide, we can heat for 10 minutes, with an additional minute for every millimetre of thickness of the Krion® LUX sheet we are using.

Carefully controlled time and temperature parameters ensure a good result.

Step 3: Moulding in the membrane press

Once the right temperature has been reached, the Krion® LUX piece is placed on the mould in the membrane press. This process applies uniform pressure to the material, allowing it to take on the desired shape. The use of combined moulds ensures that the material adapts correctly to the complex shape without deformation. Vacuum pressing, especially in projects with intricate designs, allows the material to adhere more precisely to the mould.

Step 4: Cooling and fixing the shape

Once the piece has been moulded, it is important to allow it to cool in a controlled manner to fix the shape. The material remains in the membrane press for approximately 40 minutes.

During this time, the material must cool to below 45°C, at which point it returns to its normal rigidity and stability.

Step 5: Adjustments (if necessary)

In some cases, after cooling and inspection, some final adjustments may be made to the piece, such as sanding edges or repairing small imperfections. This ensures that the final piece is ready for use without compromising its integrity or aesthetic appearance.

Thermoforming is undoubtedly one of the most outstanding techniques that allow you to explore the true versatility of Krion® LUX. This property not only opens the door to innovative shapes and designs, but also maintains all the characteristics that make Krion® LUX an exceptional solid surface.

If you have any technical questions or need guidance on how to implement Krion® LUX in your project, please contact our K® Associate Quality Fabricators or visit the exclusive services offered by A&D and Affinity. These programmes are designed to provide ongoing support and expert advice to professionals, ensuring that every project is a success, from the design phase to the final installation.