Solid surface tubs, also known as stone resin tubs, are crafted using a blend of aluminum hydroxide, unsaturated polyester resin, and other mineral materials. The production process involves multiple steps to ensure durability, seamless design, and a flawless finish.
1. Casting
The production begins by mixing the mineral materials in a vacuum tank to ensure thorough blending. The liquid mixture is then poured into a mold.
- The material is left to solidify in the mold for at least 1 hour.
- Once solidified, the tub is removed from the mold, and quality inspectors check to ensure it meets production standards before moving to the next step.
2. Cutting and Drilling
The next step involves precision machining:
- The bottom of the tub is cut to ensure it is perfectly level with the ground.
- Openings for the overflow and drain are carefully drilled to meet design specifications.
3. Sanding and Polishing
This is the most labor-intensive and critical phase, ensuring a flawless surface:
- Every tub, including its bottom, is hand-sanded using a range of sandpaper grits:
- Starting from coarse 60-grit to fine 600-grit for matte finishes.
- For glossy finishes, sanding continues up to 1500 grit, followed by polishing.
- Workers use intense lighting at a 45-degree angle to inspect and sand the surface.
- The tub is hand-checked for smoothness, and any imperfections are marked, re-sanded, and polished until the surface is flawless.
- After sanding, quality inspectors use high-powered flashlights to ensure there are no visible flaws, requiring rework if necessary.
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