INSIDE THE WORKSHOP

The Work Behind the Surface

Step 1:Read the Wood First

A finished epoxy table can look seamless, but it is created through a sequence of technical stages. Material preparation affects resin work; curing affects when shaping can begin; sanding influences the final sheen.

Before cutting or pouring, the slab must be understood. We consider usable dimensions, grain movement, natural edges, structural condition, color, thickness and the relationship between multiple pieces.

For river tables, slab orientation changes the center opening. For waterfall forms, continuity and geometry require additional planning.

· Slab planning

· Layout

· Resin preparation

· Curing

· Flattening and shaping

· Progressive sanding

· Surface finishing

· Final inspection and packing

Step 2:Establish the Composition

Once the material direction is clear, the layout is developed around the finished dimensions. The goal is not always symmetry. Controlled asymmetry can feel more natural when it follows the slab.

Small changes in position can alter river width, end balance and visual movement. Preparation then addresses the surfaces and edges that will interact with resin.

Complex effects may require several planned resin stages rather than one pour, especially when color layers, decorative details or ocean-inspired work are involved.

Step 3:Pour, Cure and Shape

Resin is developed according to opacity, transparency, color and movement. Deep black, transparent smoke, clear resin, saturated color and metallic effects behave differently in the finished piece.

Curing time is functional, not cosmetic. The material must reach an appropriate stage before later machining and surface work can continue.

After stabilization, flattening, trimming and shaping establish the final geometry. Edge and corner profiles are refined according to the selected design.

Step 4:Refine, Finish and Inspect

Progressive sanding removes machining marks and prepares wood and resin for the intended finish. The transition between materials should feel cohesive rather than like two unrelated surfaces joined together.

The finishing system establishes sheen and contributes to everyday protection. Completed furniture is then reviewed for dimensions, surface consistency, resin details, edges, corners, structural condition and base compatibility.

If an area needs additional attention, finishing may continue before the piece is cleared for protective freight packing.

Step 5: Mold Assembly

Apply up to two thin layers of epoxy to the freshly cut edges, allowing 12–18 hours for partial curing to reduce resin seepage and trapped air during the pour.

Step 6: Release Agent Application

A specialized release agent for epoxy molds is sprayed evenly across the inner surfaces in two separate coats. Each layer is given a brief drying period before the next application, ensuring complete coverage and allowing the cured resin piece to separate cleanly without damaging its finish.

Step 7: Epoxy Mixing

The epoxy is first inspected for any cold-induced crystallization and gently warmed when necessary to restore a smooth, fluid consistency. It is then transferred into large mixing vessels and blended with a low-speed power mixer for at least 4 minutes, carefully scraping the sides and bottom for an even mixture. Finally, the blended resin is vacuum-degassed for 30–60 minutes to remove fine trapped air bubbles.

Step 8: Resin Casting

The epoxy is poured gradually in multiple layers to minimize trapped air inside the resin. After every pour, surface bubbles are carefully removed using a heat gun or torch. Most tabletops require around 3–5 layers, while more detailed swirl effects may need additional pours. Each layer is allowed to cure for about 48 hours, with the final top layer resting for at least 72 hours to achieve a complete cure.

Step 9: Curing & Texture Shaping

The epoxy is typically built up in 3–5 separate pours depending on the desired tabletop thickness, while more complex flowing or swirl designs may call for extra layers. Around 12 hours after each pour, while the resin remains slightly workable, craftsmen shape fine surface patterns using scrapers, detailing combs, and controlled heat tools, repeating the process until the intended texture is achieved. Each layer is left to harden for approximately 48 hours before another pour is added. The thicker finishing layer is cured for at least 72 hours to produce a clear, smooth, and bubble-free surface.

Step 10: Mold Removal

Once the epoxy tabletop has completely hardened, all screws securing the mold are carefully removed. Each mold wall is then gently tapped with a rubber mallet to loosen the edges. Wooden wedges are gradually inserted along the sides to separate the panels, allowing the cured tabletop to be released and lifted out safely without damaging its surface.

Step 11: Fine Surface Sanding

Fill minor surface flaws with an epoxy blend and level them smooth. Sand progressively from 100 to 320 grit using a power sander, following every grit in sequence to achieve a flat, uniform, and silky finish.

Step 12: Final Buffing

Soft foam polishing pads are attached to low-speed electric polishers, and the surface is buffed gradually for around 30–60 minutes. This controlled process creates a clear, glossy, and exceptionally smooth finish while reducing heat buildup in the epoxy and preventing visible polishing marks or uneven streaks.

Step 13: Protective Surface Coating

The tabletop receives five to six coats of protective finish, with light polishing performed after each application to keep the surface smooth, uniform, and free from visible flaws. The final sealing layer is then sprayed inside a vacuum-controlled chamber, helping prevent airborne dust from settling on the surface and preserving a clean, refined final appearance.

Step 14: Final Inspection & Secure Packing

Every finished piece undergoes a detailed inspection to verify the surface quality, overall condition, and structural strength. For shipping, we use multiple protective materials including foam padding, fabric wrapping, cardboard sheets, corner guards, and custom-built wooden crates. This layered packing method helps keep the furniture well protected and reduces the risk of damage during long-distance delivery.