How to make a solid surface led bar counter?
As a manufacturer of customised solid surface stone furniture, we will explain in detail how you can easily create a luminous solid surface bar in 9 steps:
1. 3D design rendering:
We will determine the materials and colours to be used and the styling according to your needs. Pick the colours, sizes and shapes as well as other functional settings to create a 3D model of the bar.
2. Material selection
- Solid Surface Material Selection: YHS typically uses high quality solid surface materials such as Corian, Hi-Macs, or their proprietary blends.
These materials are chosen for their durability, seamless appearance, and ability to transmit light when used with LED lighting.
The surface is sanded and polished to provide a matte or glossy effect finish.
Typically the thickness is around 10mm so as to maintain the toughness of the product whilst optimising the luminous effect.
3. Colour and pattern: There are many kinds of luminescent boards available, you can customize the imitation marble pattern, they will be YHS workers handmade pattern, unique solid surface luminescent boards, you can also pick some famous brands into corian, LG and so on the luminescent boards.
4. Manufacturing process.
Model frame building: use 304 stainless steel square tube to build the product model, as shown in the picture:
Usually we keep a 25*25*1mm size stainless steel tube around 10cm, as the internal structural support to ensure that they will not be deformed and concave for a long time.
Plywood Covering: Select 12-18cm plywood (thickness depends on the model) to cover the entire surface of the stainless steel frame, and use specific nails for strong fixing.
- Cutting and Moulding: A CNC machine is used to cut the solid surface material to the specified dimensions in order to obtain precise edges and curves. For luminous parts we often use 10mm, for regular countertops we often use 12mm thick solid surface sheet. Then we fix them to plywood using artificial stone specific colour matching glue, for curved and shaped parts we put the sheet in a high temperature oven, take it out and put it into the model with a jig to fix it until it cools down and use artificial stone glue to glue it in place.
YHS can incorporate intricate shapes and custom designs, including engravings or logos, and can be backlit for added effect.
- Seamless Joints: The parts of the solid surface are joined using specialised adhesives to form invisible joints, ensuring a smooth, continuous surface and enhancing the aesthetics of the bar.
Sanding and Polishing: A special sander for artificial stone is usually used with aluminium sandpaper, 240grift sandpaper can meet the regular brightness. From coarse to fine gradually polishing rotating circle sanding.
- LED wiring: The channels are wired to the underside of the countertop or to the back of the panel where the LED strips will be placed. This ensures that the lighting is integrated without spoiling the stylish look of the bar.
5. LED Installation
- LED Strip Placement: High quality LED strips are carefully installed within the wiring channels, LEDs are usually placed in areas that provide even illumination across the bar surface, RGB LEDs can be used to provide customisable colour options.
- Power and Control Systems: LEDs are connected to a low voltage power supply with wiring concealed within the bar structure. The control system usually has remote or smartphone connectivity to easily adjust light intensity and colour.
6. Assembly and Finishing
-Surface Finishing: Solid surfaces are sanded and polished to achieve the desired effect, whether matte, satin or gloss. This step ensures a smooth and flawless surface.
-Final assembly: the pole is assembled and all components, including the lighting and any additional features, are integrated into the final structure. The pole is tested to ensure that the lighting works perfectly and that the surface is flawless.
7. Quality Check
-Lighting test: YHS carries out a thorough check of the lighting to ensure that it glows evenly and meets the client's expectations. Any hot spots or uneven lighting are addressed at this stage.
-Durability check: The strength and stability of solid surface materials are checked. YHS ensures that the bar can withstand the rigours of use, including resistance to stains, scratches and impacts.
8. Installation
- On-site installation: Shipped as a whole and packed as a whole. Customers can open the wooden box and use it. Oversized pieces will be divided for the product, pre-built screws, tighten the screws can be used
- Final Adjustment: After installation, final adjustments will be made to the bar, including adjusting lighting and verifying all controls.
9. Maintenance and support
- Maintenance Instructions: YHS provides customers with detailed maintenance instructions for solid surface materials and LED lighting systems. This includes cleaning and maintenance instructions to ensure the bar remains in pristine condition. Refer to the blog for maintenance instructions.
- After Sales Service: YHS provides ongoing support for any issues that may arise, ensuring long term satisfaction with the product. Refer to the YHS after sales service blog.
If you are interested in building an illuminated bar with YHS, please feel free to contact us via email at info@yanhesheng.com or send us an enquiry. Get a quick quote.
