1. DuPont™ Corian® Private Collection Series
Fabrication Considerations
2010

2. Private Collection Series Characteristics
The Private Collection Series has characteristics that requires some specific fabrication methods
Directional veining that ranges from subtle to bold
The edge of the sheet has a different appearance than the top
The shade may change slightly through the thickness
Some colors have abrasive content that shortens tool life
Sheet yield may be lower – need to consider when quoting jobs
It is important to understand these characteristics and be able to set customer expectations
Physical samples help in setting expectations
The Private Collection Series has characteristics that requires some specific fabrication methods such as:
Directional veining that ranges from subtle to bold
The edge of the sheet has a different appearance than the top
The shade may change slightly through the thickness
Some colors have abrasive content that shortens tool life
Sheet yield may be lower – need to consider when quoting jobs
It is important to understand these characteristics and be able to set customer expectations
Physical samples help in setting expectations

3. Veining Directional Random Edge appears different
Need to consider sheet orientation when seaming
Random
Unless you have two consecutive sheets there will be a break in the pattern when seaming
Edge appears different
Have side view of vein
Veins vary through thickness
Cutting into sheet (rebating, coving) will reveal a different vein pattern
Vein influence on background color stronger on the surface
Interior of sheet may have slightly different shade
So you need to consider the following when fabricating the private collection series:
First the veining in the Private Collection colors is directional so you need to consider the orientation of the sheet when seaming sheets together.
The veining is also random, it does not repeat like other materials such as wallpaper or flooring. So when seaming long runs (over 12ft) consecutive sheets need to be used to minimize the appearance of a break in the pattern at the seams.
The veining in the edge of the sheet appears different and is apparent when cutting coves for backsplashes or rebates for edge buildups. This is due to the varying intensity of the veining through the thickness of the sheet.
The vien also influences the appearance of the backround color of the sheet as it varies in intensity through the thickness of the sheet.
So the interior of the sheet may appear slightly different in shade than the surface.

4. Directionality Definitions
MD – Machine Direction (along length)
TD – Traverse Direction (along width)
The veins generally run along the length (MD)
Most uniform appearance is when all sections run the same direction
Avoid MD-TD (90°) Butt Seams
Let’s look at a couple of definitions that pertain to the directionality.
There is machine direction which it the length or end to end direction and
Traverse direction which is the width or side to side direction.
In general the vein runs in the machine direction of the sheet.
The most uniform appearance is achieved by orienting the vein in the same direction.
Avoid orienting the sheet in Machine direction to Traverse direction especially at 90 degree butt seams. MD TD

5. Seaming 1 2 3 4 Recommended Not Recommended (1) End to End (MD-MD)TD 1
Recommended
(1) End to End (MD-MD)
Side to Side with same orientation
(2) MD-MD
TD-TD (not shown)
(3) Miter Seam
Not Recommended
(4) MD-TD Butt Seam MD TD 2 MD TD 3
This slide shows the recommended orientation for seaming various configurations:
Example 1 illustrates the orientation of the sheets when long expanses are seamed from more than one sheet. In this scenario the sheets should be seamed end to end keeping the vein running in the machine direction.
Example 2 illustrates one option for orienting sheets in an “L” shaped configuration. In this scenario the vein is kept in the same direction by cutting a 30” section for the leg of the top so that the vein in the leg maintains the machine direction of the main section of the top.
Example 3 illustrates utilizing a mitre seam at the corner of an “L” shaped top and orienting the sheets with the machine direction pointed to the corner on either side. This is a typical method for dealing with products with linear patterns and is an appearance that most consumers are familiar with.
Example 4 illustrates an orientation of an “L” shaped top that should be avoided. This orientation intensifies the appearance of the pattern change in the corner of an “L” shaped top. Most consumers would not accept this appearance. MD TD 4

6. Mockup Contains: Mitered Seam MD-TD Seam MD-MD Seam Coved Backsplash
Drop Edge
Stack Edge
V-Groove Edge
This slide shows a mock up the methods used to fabricate a typical countertop. This mockup has most of the methods for fabrication included in it such as:
Mitered Seam
MD-TD Seam
MD-MD Seam
Coved Backsplash
Drop Edge
Stack Edge
V-Groove Edge

7. Mockup Contains: Mitered Seam MD-TD Seam MD-MD Seam Coved Backsplash
Drop Edge
Stack Edge
V-Groove Edge
Now let’s put some lines into the picture to show these methods.
You can see the mitre corner as the angled line in this picture. Due to the subtle pattern In this color the mitre corner blends well and looks fairly uniform.
The line at the top right side of the picture shows an MD-TD seam. Although in this picture the appearance using this color is fairly uniform it is recommended to avoid MD-TD orientation of seams in Private Collection colors
The line at the lower left side of the picture shows an MD-MD seam by using a 30” section for the leg and orienting the vein to match the MD direction of the other section. Notice how this blends better than the MD-TD even in a light pattern color.
This also has examples of a drop edge, stack edge and v-groove edge. We will talk about them later in this presentation.

8. Mockup – Sorrel (Stronger Pattern)
Contains:
Mitered Seam
MD-TD Seam
MD-MD Seam
Coved Backsplash
Drop Edge
Stack Edge
V-Groove Edge
In this slide the same fabrication methods are illustrated in a stronger pattern. It’s easy to see how a strong pattern impacts what fabrication method is used to make the top.
Notice in the top right side of the picture how the MD-TD seam is very noticeable and probably not acceptable by most consumer standards.
The mitre seam is also noticeable but is typical of corners in materials with strong veining. Again it is an appearance that most consumers are used to seeing for this type of pattern.
You will also notice in the MD-MD seam at the bottom left side of the picture, using a 30” section for the leg and orienting the vein to match the MD direction of the other section, the pattern does not match exactly but blends much better than an MD-TD seam.
This also illustrates the importance of using mock ups or picture to set consumer expectations.

9. Edge Buildups V-groove Edge 1 (2) Stacked Edge (3) Drop Edge 2 3 top
“top” of sheet visible on both surfaces
Pattern can “flow” over edge
Good with minimal radius
(2) Stacked Edge
Edge of sheet visible, see edge of veins
Not identical to top of sheet, but “flows”
Works well with many profiles
May see “layers”
(3) Drop Edge
Side view has edge of top sheet, “top” of dropped edge
Visible pattern difference for most Private Collection colors
top
edge 1
top
edge 2
Next we’ll take a look at how each of the methods for fabricating buildup edges works with Private Collection colors.
The V-groove edge provides the best appearance. Because the top of the sheet ends up being visible on both surfaces and the pattern flows over the edge the appearance achieved with a V-groove edge is the most uniform. A minimum radius edge works best with the V-groove method.
If you don’t have V-groove capability in your shop, the next best edge buildup method is the stacked edge. The look is not as uniform because edge of the sheet is visible which is not identical to the top of the sheet, but it does flow well with most colors. The layers of veining may be seen using this method, especially in colors with strong vein. This method works with many edge profiles.
The drop edge buildup gives the least uniform look. In the drop edge the edge of the sheet contrasts with the face of the buildup strip normally yielding an appearance that doesn’t measure up to most consumers standards. This edge method should be avoided for most Private Collection colors.
top 3
edge

10. Edge Buildups V-groove Edge 1 (2) Stacked Edge (3) Drop Edge 2 3
“top” of sheet visible on both surfaces
Pattern can “flow” over edge
Good with minimal radius
(2) Stacked Edge
Edge of sheet visible, see edge of veins
Not identical to top of sheet, but “flows”
Works well with many profiles
May see “layers”
(3) Drop Edge
Side view has edge of top sheet, “top” of dropped edge
Visible pattern difference for many Private Collection colors 1 2
Here you see pictures how the three edge buildup methods look.
Number one using the V-groove method has a very uniform transition from the top into the buildup
Number two using a stacked buildup still gives a good uniform appearance but does show the layers of pattern in the buildup pieces.
Number three using the drop edge noticeably shows the contrast between the edge of the top and the face of the buildup. 3

11. Coved Backsplashes
Coves have two transitions in a short distance (deck-cove-backsplash)
There is a visual break in pattern
Some colors may appear a different shade in the cove
Veins may be more prominent in cove
Some colors with more subtle patterns may work
Best practice is to show customers physical samples to set expectations.
Coved backsplashes have an extra consideration. Because a coved backsplash has two transition lines, one at the deck and one at the backsplash, it creates an appearance that shows a break in the pattern in two places within a short distance.
In addition, the cove cut goes deeper into the sheet thickness exposing an area of the sheet that can have more or less intense veining than the surface of the sheet. This can also cause the cove piece to have a different shade than the surface of the sheet.
Some colors with more subtle pattern may work but a best practice is to show the consumer a physical sample to set proper expectations.

12. Alternate Corner Designs
Variations of Mitre corners
Stepped
Swooped
Fan
Alternatives to straight mitre
Must have proper seam support strip
Seam support strip must be supported properly
Seam support must be filled completely with adhesive
Higher cost to consumer helps to blend the pattern for better appearance
There are some alternate corner designs being used in the market such as:
A stepped corner, a swooped corner and a fan design to name few. An “S” pattern has also become popular in some areas. These methods are basically variations of a mitre corner using various shapes to blend the transition of the pattern at a corner.
These are acceptable alternatives to the straight mitre corner if the following required fabrication requirements are followed:
The seam must have a proper Corian seam support strip
The Corian seam support strip must be supported at both ends
The Corian seam support strip must be completed filled with joint adhesive
Naturally these alternate corner designs will mean a higher cost to the consumer but if the additional cost is acceptable they can offer a nicer look in the finished appearance of the installation.

13. Alternate Corner Designs
Stepped
This drawing shows the stepped corner. In this design the seam configuration is made in a step pattern and the seam is offset to one side of the corner.
The seam plate must be sized so that it extends past the step design at least 1” on both sides.
The “S” design which has become popular recently is a variation of the stepped corner. The same requirements apply to this design.

14. Alternate Corner Designs
Swoop
The swoop corner is another variation of the step design using a arc shape. This again is offset to one side of the corner.

15. Alternate Corner Designs
Fan
The fan design uses pie shaped wedges to create a gradual transition of the pattern through the corner. This is the most labor intense method and most costly. All of the seams must be reinforces the same as the other alternate designs.

16. Other Considerations
Some colors have ingredients that increase tool wear
Ecru, Cirrus White, & Natural Gray (Camel – Library Color)
Private Collection colors can appear to be “softer” when finishing
Use care to get the proper finish
Thermoforming
Heat to the lower end of the recommended range ( °C / °F)
Some other considerations are:
Ecru, Cirrus White and Natural Gray along with the library color Camel have ingredients that increase tool wear in router bits and cutting blades. More frequent sharpening may be required for bits used with these colors.
Private Collection colors can appear to be “softer” when finishing. Following suggested finishing techniques such as “pattern sanding” and cleaning the surface thoroughly between finishing steps will help create a uniform finish.
Thermoforming should be completed by heating the material at the lower end of the recommended range degrees and also bending as gradually as you can when placing the material in the mold.

17. Summary
Private Collection colors have large scale patterns that require some extra considerations
Design and price with directionality in mind
Don’t base pricing on area and sheet price, yield may be lower to keep segments in the right orientation
Not all fabrication methods are suitable, those that work with subtle patterns may not work with bolder patterns
Some colors have abrasive content that shortens tool life
Avoid surprises
It is important to understand these characteristics and be able to set customer expectations
Physical samples help in setting expectations
So in summary:
Private Collection colors have large scale patterns that require some extra considerations
Design and price with directionality in mind
Don’t base pricing on area and sheet price, yield may be lower to keep segments in the right orientation
Not all fabrication methods are suitable, those that work with subtle patterns may not work with bolder patterns
Some colors have abrasive content that shortens tool life
Avoid surprises
It is important to understand these characteristics and be able to set customer expectations
Physical samples help in setting the customers expectations

18. The information contained in this presentation is given by the E. I
The information contained in this presentation is given by the E. I. du Pont de Nemours and Company free of charge. It is based
on technical data which DuPont believes to be reliable and is intended for use by persons having knowledge of this technical area at
their own discretion and risk. Seller assumes no responsibility for results obtained or damage incurred from the use of this presentation either in whole or in part by a buyer of DuPont™ Corian® solid surfaces.
Copyright 2010 E.I. du Pont de Nemours and Company.
DuPont™ Corian® is a registered trademark of E.I. du Pont de Nemours and Company