How It's Made
Step 1: Layout Design
Craftsmen use scrap 1x1 inch wooden strips to construct a frame that fits the exact dimensions of the finished tabletop. The wood pieces are thoughtfully arranged following their natural curves to maintain the wood’s grain and edges. Cutting lines are marked with chalk or a pencil, with a 1‑inch allowance left for final trimming.
Step 2: Cutting Slabs to Size
Boards are trimmed to the marked dimensions, eliminating softwood, bark, and any decayed sections—only firm, healthy wood is kept. Clean, accurate cuts ensure smooth, gap-free resin application.
Step 3: Cleaning Up the Slabs
Small and hard-to-reach spots are cleaned using a drill‑attached nylon brush to preserve the wood’s natural texture.
Step 4: Edge Sealing
The cut edges are sealed with 1–2 coats of epoxy resin and allowed to semi-cure for 12–18 hours. This prevents resin from bleeding out and air bubbles from forming during the casting process.
Step 5: Building the Mold
Smooth MDF panels are used to construct a mold that is roughly 2 inches larger in length and width than the cut slabs, and 2 inches taller than the wood thickness. All joints are sealed with quick-drying adhesive to ensure a leak‑proof mold. The mold is left to cure for 24 hours before casting.
Step 6: Applying Mold Release
A specialized epoxy mold release agent is sprayed twice inside the mold. Each coat is spread evenly after a short drying time, ensuring clean, damage-free demolding.
Step 7: Mixing Resin
First, check the epoxy resin—if crystallization occurs due to cold temperatures or environmental factors, gently warm it to restore its fluidity. Next, pour the resin into large buckets and mix it with a low-speed electric mixer for no less than 4 minutes, making sure to thoroughly scrape the sides and bottom of the bucket to ensure uniform mixing. After mixing, place the mixture in a vacuum chamber to degas for 30 to 60 minutes, which removes any fine air bubbles.
Step 8: Pouring Epoxy
Epoxy is poured slowly in layers to minimize air entrapment. After each layer, surface bubbles are removed with a torch or heat gun. Typically, 3–5 layers are cast; complex swirl designs require more. Each layer cures approximately 48 hours; the final layer requires 72+ hours.
Step 9: Curing & Texture Refinement
Typically, 3–5 layers of epoxy are poured depending on the desired thickness, with additional layers required for complex swirl patterns. Approximately 12 hours after pouring—when the resin is still low in viscosity—craftsmen refine the textures using scrapers, fine combs, or heat tools, repeating the process as needed to achieve the ideal finish. Each layer must cure for 48 hours before the next layer is applied. The final, thicker top layer requires over 72 hours of curing to ensure a bubble-free, clear, and smooth surface.
Step 10: Demolding
Once cured, screws securing the mold are removed. The mold sides are gently tapped with a rubber mallet and carefully pried away with wooden wedges to safely release the tabletop.
Step 11: Sanding
Fill defects with epoxy resin mixed with hardener, then smooth it flush with the surface. Use a sander to gradually sand with 100, 120, 150, 180, 240, and 320 grit sandpapers in sequence, avoiding skipping grits to ensure a smooth, even finish.
Step 12: Polishing
Using a low-speed electric polisher fitted with a soft foam pad, perform staged polishing for 30–60 minutes. This achieves a clear, smooth surface while guarding against overheating and uneven results.
Step 13: Surface Finishing
Apply 5–6 coats of protective finish, polishing the surface between each coat to ensure a uniform, flawless finish. Finally, apply the sealing topcoat in a vacuum chamber to effectively prevent dust contamination.
Step 14: Quality Control & Packaging
Every finished piece undergoes rigorous inspection to ensure a flawless surface and solid structural integrity. The packaging comprises five protective layers: foam, fabric, cardboard, edge protectors, and a custom wooden crate. This comprehensive packaging solution guarantees safe delivery, even for long-distance transportation.