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Standard-format sintered stone panels suit many applications, but the majority of architecturally significant projects require precision-cut components tailored to specific dimensions, joint layouts, and design features. Whether it's a kitchen island with an integrated sink, a facade panel with window cutouts, or a feature wall requiring book-matched veining, custom cut sintered stone fabrication capabilities are essential for translating design intent into finished reality.
This guide covers the technical aspects of custom sintered stone cutting and fabrication, including tolerances, edge profiling capabilities, and specification practices that ensure fabricated components meet project requirements.
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Cutting Technology
Modern sintered stone customisation is performed on CNC (computer numerical control) machines using diamond tooling. Two primary cutting methods are employed:
| Method | Technology | Typical Application | Edge Quality |
| Waterjet cutting | High-pressure water mixed with abrasive garnet | Complex shapes, internal cutouts, thick panels (12mm+) | Clean edges, slight satin finish |
| Diamond blade (bridge saw) | Continuous-rim diamond blade on CNC bridge saw | Straight cuts, mitered edges, panel sizing | Polished edge with minimal finishing required |
Precision Tolerances
| Dimension | Standard Tolerance | Precision Tolerance (special request) |
| Length and width | ±1.0mm | ±0.5mm |
| Thickness | ±0.3mm | ±0.2mm |
| Diagonal (squareness) | ±2.0mm over 2700mm | ±1.0mm over 2700mm |
| Cutout position | ±1.5mm | ±0.5mm |
| Edge profile consistency | ±0.3mm | ±0.2mm |
| Internal corner radius (minimum) | 5mm | 3mm (waterjet) |
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Standard Edge Profiles
| Profile | Description | Recommended Applications | CNC Tooling Required |
| Square (eased) | Slight 1mm chamfer on exposed edges | Contemporary minimal aesthetic, external cladding | Standard |
| Chamfer (bevel) | 45° angle, 10–20mm depth | Benchtops, step treads, modern facades | Standard |
| Bullnose (half-round) | Rounded top edge, 10–20mm radius | Pool coping, step edges, shower shelves | Standard |
| Full bullnose | Completely rounded edge | Shelf edges, step nosings | Standard |
| Mitered | 45° joint for seamless corner assembly | Benchtop waterfall edges, countertop corners | Standard |
| Dupont (ogee) | S-curve profile | Traditional benchtops, decorative features | Specialised |
| Chiseled (split face) | Natural stone-like irregular edge | Feature walls, fireplace surrounds | Manual finishing |
Laminated Edge Details
For kitchen benchtops and horizontal surfaces, a popular detail is the laminated edge — where the visible edge appears thicker than the surface panel:
| Configuration | Surface Panel | Substrate Panel | Visible Edge Thickness | Process |
| Standard laminated edge | 6mm | 6mm | 12mm | 45° miter join, epoxy bonded |
| Heavy laminated edge | 6mm | 12mm | 18mm | 45° miter join, epoxy bonded |
| Ultra-thick laminated edge | 6mm | 20mm | 26mm | 45° miter join, epoxy bonded |
The mitered joint between surface and substrate is precision-machined at 45°, bonded with two-part structural epoxy, and clamped during curing. The result is a seamless joint visible only under close inspection.
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Sink Cutouts
| Cutout Type | Description | Precision Required |
| Undermount (rectangular) | Rectangular opening with polished reveal edges, 2–3mm smaller than sink dimensions | ±1.0mm |
| Undermount (radius) | Radiused corners matching sink profile, polished reveal | ±1.5mm |
| Integrated basin | CNC-carved from the panel, forming a seamless sink basin | ±1.0mm |
Cooktop Cutouts
- Rectangular cutout matched to cooktop specifications
- Polished reveal edges
- Radiused internal corners (minimum 5mm radius)
- Position tolerance: ±1.5mm from design coordinates
Tap and Fitting Holes
- Standard 35mm diameter hole for mixer taps
- Diamond core drilling for clean edges
- Position tolerance: ±2.0mm
Switch and Outlet Cutouts (for Sintered Stone Splashbacks)
- Rectangular cutouts for electrical accessories
- Polished edges visible behind cover plates
- Size tolerance: +2mm per dimension (slightly oversize to accommodate fitting adjustment)
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Available Finishes
| Finish | Surface Character | Suitability |
| Polished | High gloss, mirror-like reflection | Kitchen benchtops, indoor feature walls, reception surfaces |
| Matte | Smooth, non-reflective | Kitchen benchtops (low-glare), splashbacks, bathroom surfaces |
| Honed | Satin sheen, fine texture | Bathroom floors, shower walls, interior flooring |
| Structured | Textured, tactile surface | Exterior facades, pool surrounds, anti-slip flooring (R12–R13) |
Finish Combination Options
Some projects benefit from combining finishes on a single panel:
- Split finish: Polished on the front face, matte on the back face (for cabinet cladding where the back face is visible through open shelving)
- Zone finish: Polished central area with honed border (for benchtops where a specific zone requires different slip or maintenance characteristics)
- Textured feature band: Honed field with structured finish inset strip (for feature wall accent details)
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What Is Book Matching?
Book matching is the technique of placing two adjacent panels so their surface patterns mirror each other — analogous to opening a book. This creates a symmetrical, premium visual effect particularly valued for:
- Kitchen island panels (vertical faces)
- Feature walls behind cooktops or fireplaces
- Reception desk front panels
- Bathroom feature walls
Specification Requirements for Book Matching
Pattern direction marking: Each panel must be marked with the pattern orientation direction at production
Cutting sequence: Panels must be cut from a single production batch, in a specific sequence to maintain pattern continuity
Installation layout plan: A digital layout showing panel position, orientation, and joint locations must be approved before fabrication
Tolerance for pattern shift: Expect ±5–10mm pattern displacement between adjacent panels — this is inherent to the manufacturing process and should be accepted in the design
Veneer Matching Options
| Matching Type | Description | Complexity | Premium |
| Random | No matching — panels installed in any order | Standard | None |
| Sequential | Adjacent panels from same production sequence | Moderate | +5–10% |
| Book match | Mirrored pattern on adjacent pairs | High | +10–15% |
| End match | Book matching across four panels (full mirror) | Very high | +15–20% |
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Required Information
A complete custom fabrication specification should include:
- [ ] Panel dimensions (length × width) with tolerance requirements
- [ ] Thickness specification
- [ ] Surface finish (and which face if different)
- [ ] Edge profile for each edge (top, bottom, left, right)
- [ ] Cutout dimensions and positions (sinks, cooktops, tap holes)
- [ ] Laminated edge details (if applicable)
- [ ] Pattern matching requirements (book match, sequential, or random)
- [ ] Colour selection (colour code, name, and reference sample)
- [ ] Quantity per size and configuration
- [ ] Project name and delivery requirements
Drawing Format
- Preferred: CAD (DWG or DXF) with clearly dimensioned panels
- Alternative: Detailed dimensioned sketch with all specifications noted
- Include: Panel layout plan showing position and orientation of each piece
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Pre-Shipment Checks
| Dimensional accuracy | Within specified tolerance (see table above) |
| Edge profile consistency | Uniform, no chipping or irregularity |
| Cutout accuracy | Within ±1.5mm of specification |
| Surface quality | No scratches, chips, or marks |
| Colour matching | ΔE < 1.0 to reference sample |
| Lamination bond | No visible joint line, no delamination |
| Packaging | Individual protection for each piece, A-frame or flat-pack as appropriate |
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| CNC machinery | 5-axis CNC bridge saw + waterjet cutting |
| Maximum panel size for cutting | 1600 × 3200mm |
| Edge profiles | All standard profiles + custom shapes |
| Cutout types | Sink, cooktop, tap, switch, custom shapes |
| Book matching | Sequential and book match available |
| Lamination | 6+6mm, 6+12mm, 6+20mm configurations |
| Lead time (cut-to-size) | 15–20 working days from order confirmation |
| Lead time (custom shapes) | 20–25 working days |
| Minimum order | No minimum — single custom pieces accepted |
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Custom cut sintered stone fabrication transforms large-format panels into precisely tailored components that meet exact project requirements. The key to successful custom fabrication is clear specification documentation, realistic tolerance expectations, and a manufacturer with proven CNC capabilities. When these elements align, the results are seamless, precise installations that realise the full design potential of sintered stone.
Wharton offers full custom cutting, edge profiling, and fabrication services with CE and ANSI certified materials. Request free samples and a custom fabrication quote at whartonceramics.com/contact/sample, or send your project drawings on WhatsApp at +86 139 2313 0743 for a tailored response.