Corian/Epoxy Plaque

[Holzarbeiter]

This is a plaque I came up with to honor a lady at our church who has been playing the piano, organ and singing
in our choir for 55 years. We honored her at a recognition dinner a month ago.

The plaque measures roughly 16 x 16 and it is 0.5" thick. Since I could not find any solid black Corian I had to create the piano shape as an epoxy inlay, approximately 0.1 deep. I just painted the edges black to match...easy peasy! The clef & rest artwork I purchased online. I simply love doing epoxy inlays in Corian. It is such a nice material to cut, and there is no worries about colors bleeding!

[TomWS]

Very striking plaque!

Can you explain your 'inlay' technique a bit? Do you VCarve the inlay region and then pour the mixed epoxy into it? I would expect it to be less even and with bubbles. Yours is immaculate!

BTW, I agree with you on vcarving corian. Very nice material to work with.

[Leo]

That is absolutely BEAUTIFUL.

[Holzarbeiter]

Very striking plaque!

Can you explain your 'inlay' technique a bit? Do you VCarve the inlay region and then pour the mixed epoxy into it? I would expect it to be less even and with bubbles. Yours is immaculate!

BTW, I agree with you on vcarving corian. Very nice material to work with.

Thank you!
Yes, I vcarve out the area to be filled, about 0.1 deep. Before pouring the epoxy I level the piece with shims, otherwise the epoxy flows to one side or the other…not good! After its poured I watch for bubbles and when they start showing up I spray them with denatured alcohol. It does a super job dispatching the bubbles. In the first 20 minutes or so after pouring the epoxy I will usually have to spray two, maybe three times and thats all. I make sure the epoxy mounds up in the carve, then when I go to skim it everything is nice and flat. I hope that answers your question…holler if I missed something.

[Holzarbeiter]

That is absolutely BEAUTIFUL.

Thank you, Leo!

[Todd D]

Really nice work, I also like to cut in Corian and may try your method with epoxy. At the moment I'm experimenting with the zank type of inlay in Corian and it looks promising.

[Holzarbeiter]

Thank you, Todd.
I have to admit, I too have been wondering how the zank inlay would work. Your results have me even more
excited to give it a try. Thanks for sharing!

Just out of curiosity, what type of glue did you use for the inlay? I have used CA glue to laminate pieces and that worked quite well.

[TomWS]

After its poured I watch for bubbles and when they start showing up I spray them with denatured alcohol. It does a super job dispatching the bubbles. In the first 20 minutes or so after pouring the epoxy I will usually have to spray two, maybe three times and thats all.

Ah, I haven't heard of that technique before. Good to know! THANKS!

I make sure the epoxy mounds up in the carve, then when I go to skim it everything is nice and flat. I hope that answers your question…holler if I missed something.

How do you 'skim'? Sand, machine on the CNC, ???

Thanks for the detailed answer. I'm sure others will be experimenting with this now!

@ToddD, good job on the Corian inlay. Good to know this works as well!

This is a terrific resource!!!

[Creation in Wood]

Great job Joe

[Todd D]

Thank you, Todd.
I have to admit, I too have been wondering how the zank inlay would work. Your results have me even more
excited to give it a try. Thanks for sharing!

Just out of curiosity, what type of glue did you use for the inlay? I have used CA glue to laminate pieces and that worked quite well.

I tried epoxy and then ca glue with not so good results, then I was able to get the Corian branded glue the counter top guys use. It is color coded to the white and a seamless result. Very hard to get glue as its only sold to fabricators.

[garylmast]

Beautiful job. I'm going have to give your technique a try.

Gary

[scottp55]

Wonderful Job Joe!!
Really Beautiful work:)
scott

[Holzarbeiter]

Doug, Gary and Scott, thank you for the kind comments.

[Holzarbeiter]

TomWS,

I have a drum sander but I was always afraid of clogging up the sandpaper so I skim it on the cnc.
I set Z0 to the surface of the material (where there is no epoxy) and then set my depth of cut to 0.002
That does a nice job of removing the domed epoxy and making everything nice and flat. When Im using epoxy on
Corian I use an O flute bit as it puts a nice smooth finish on both the epoxy & Corian. For wood/epoxy projects I use
a regular end mill.

[TomWS]

When Im using epoxy on
Corian I use an O flute bit as it puts a nice smooth finish on both the epoxy & Corian.

You get that smooth mirror finish with your CNC router!?

I agree, O-Flutes are the way to go with plastics.