Postformed components are highly modern, look good to the observer, are easy to look after and functional for those who have to clean or work on them. Typical applications of this engineered wood processing technology are kitchen worktops with rounded, seamless edges and furniture with curved shapes. The latter are among the highlights often used in interior design. This is because high-quality interior fittings require furniture that is not only functional, but also eye-catching. So, whenever interior design calls for rounded shapes, our solution is postforming. This is where premium looks meet state-of-the-art technology. Many people have come across forming, but only very few can say what it is called. Even in the carpentry trade, it can happen that people are not aware of the term postforming and what it means. So we’re taking a detailed look at postforming technology, explaining what the term means and how we at Toms Gerber GmbH transform angular shapes into elegant curves.
Rounded edges without joints: A definition of postforming
In general terms, postforming refers to a specialised processing technique in which wooden panels and moulded parts are produced with a rounded edge. The byword is therefore “the square must be circled”. The term “postforming” in particular means that first, one or more edges of a engineered-wood component is/are rounded. A laminate panel is then placed around this pre-profiled shape, enclosing it seamlessly at the end of the machining process. As the laminate would split if it were folded at the edge of the workpiece under normal ambient conditions, the key factor for postforming technology is the application of heat. The production of these components therefore requires a great deal of precision and experience. Selecting the right coating material and adhering to precisely the right temperature and pressure are crucial to achieve a perfect result. It is also very important to select the right mould and align the panels exactly. The perfect postformed component is therefore the result of a combination of technological expertise and years of experience.
From window sills to worktops: The potential applications of postformed components
Potential applications are as diverse as the potential of postforming itself. Curved furniture components are becoming increasingly on-trend in interior design. Postformed components are especially suitable for kitchen worktops and kitchen cabinet fronts, as their rounded edges make them particularly hygienic and easy to clean. They also make them suitable for use in hospitals or laboratories. But furniture panels with postformed edges are also a good choice for window sills – both in dry indoor areas and in building complexes that are exposed to moisture.
The forming process can be undertaken with a variety of substrates and a wide range of coating materials. While substrates range from poplar plywood to ultra-light MDF, recycled PU panels and gypsum fibreboards, at Toms Gerber GmbH we coat postformed components with standard laminates, but also real-wood and sliced veneers, and even linoleum. This diversity creates a wide range of potential applications, from furniture construction and interior design to ship fittings to furnishings for camper vans and motor homes; it is also used in the interior design of hotels, restaurants and shops.
The individual steps of the postforming process
Postforming technology entails a multi-step process in which different criteria need to be taken into account in successive processes. However, the basic principle of postforming is that a thin layer of thermoplastic with a thickness of between 0.4 mm and 1.2 mm is applied to a pre-profiled panel material, such as MDF. The most common coating materials are CPL (continuous-pressure laminate) and HPL (high-pressure laminate).
By adding heat and pressure, the laminate panels are moulded into a new shape, then rounded edges without joints are created through the postforming process. Panel mouldings with L- or U-shaped profiles are just as feasible as single and double rounded edges. As a furniture component manufacturer, Toms Gerber GmbH utilises both stationary and continuous processes in production. This enables us to produce both customised individual pieces and rationalised serial parts to meet our customers’ requirements.
The stationary process is particularly suitable for the production of individual items and small batches. This allows complex operations to be executed; interior and exterior curves can be produced, or a sequence of different curves. The continuous process, on the other hand, is used to produce larger quantities and is limited to a maximum workpiece thickness of 60 mm. In this process, precisely-measured and cut strands of engineered-wood panels are prepared and fed one after the other through a special system, in which the protruding laminate is moulded onto the pre-profiled substrate using high temperatures and sets of mechanical rollers. The individual steps through which each strand passes, and which together make up the postforming process, include the profiling of the substrate panel, the use of adhesive to attach the covering layer, the moulding of the covering layer and the cooling and hardening that completes the process.
Preparation and profiling of the substrate panel
As is so often the case in life, good preparation is crucial when manufacturing postformed components. Depending on the intended use and location, there are a number of different substrates to choose from, each with their own properties. The spectrum ranges from chipboard to substrate panels made of powdered stone. It is therefore more than understandable that in postforming technology, it is essential that the preparation of the substrate panel is material-specific and precise. First, the panel is cut to the required size and the desired profile for the subsequent postformed edge is milled. It is important that the milled edges are clean and even to ensure an optimum result, which is essential for the subsequent processing steps. All milled material must be completely removed from the substrate panel so that the it can be stored free of residue for the next processing step.
Pressing the covering and reverse sides together and bonding with adhesive
The postforming process is then initiated by applying the decorative surface material to the covering and reverse sides: this is a key part of the process. The use of suitable adhesives is crucial in postforming technology in order to ensure a durable and strong bond between the substrate and the decorative material. Moisture-resistant adhesives can be used depending on where the postformed parts are to be deployed. When combined with moisture-resistant engineered wood, this ensures that the finished components with postformed edges can also be installed in bathrooms, spa areas or wet rooms.
First, the surface is glued to ensure consistent adhesion across the surface. The prefabricated substrate panel is glued in a continuous process. The laminate – often a high-pressure laminate – is then positioned precisely on the glued panel to ensure that it covers the entire surface of the panel. The composite, made up of glued engineered wood and the decorative finished surface, is then pressed together. The special feature of this process is that the laminate, which is later moulded onto the pre-profiled edge of the workpiece, is also pressed and initially protrudes over the side. This processing step therefore initially ensures that the surface material forms a smooth and resistant covering layer. However, it is the rounding that is most characteristic of preforming.
Forming in the postforming process
Forming is a difficult step in the postforming process that enables the decorative material to be seamlessly wrapped around the edges of the substrate panel. We use two different technologies for this. The main differences between them relate on the one hand to the gluing of the narrow surface to which the protruding covering layer is formed and on the other to the type of forming. In the stationary process, the adhesive is applied manually and the HPL is moulded using a pressing bar. In the continuous process, on the other hand, the edge surface is automatically glued in the machine and a large number of rollers guide the laminate onto the pre-profiled substrate. This step requires extreme precision in order not to destroy the materials, as the ideal window for processing is just before the point where damage occurs. Under the influence of heat and high pressure, the surface layer is therefore formed onto the substrate panel. By being pressed against the substrate, the covering layer takes on its shape, including all edges and curves, and the adhesive fixes them together. This process creates a seamless, aesthetically pleasing and extremely durable surface that is particularly valued for furniture, kitchen worktops and bathrooms, where high standards of hygiene and durability are required.
Cooling and hardening
The postforming process is completed by cooling and hardening – a crucial step to ensure the quality and durability of the end product. After the decorative material has been pressed and formed onto the substrate panel through the application of heat and pressure, the bent composite component must cool down so that the adhesive can harden. During this process, the bond between the laminate and the substrate becomes permanent and stable. It is important that this step be carried out slowly and evenly to avoid creating tension in the material, which could otherwise lead to cracks or deformation. After cooling and hardening, the end product is ready for final cutting, further processing into components, and packaging and prefabrication before being shipping to the customer or construction site for final assembly.
Buying postformed components
The desire to buy postformed components often stems from the need to deliver an interior design feature that requires aesthetically pleasing curves but must not be susceptible to dirt and moisture, where the material to be used has a robust structure. The need for a seamless and smooth surface means prospective customers inevitably end up with postformed panels, which are easy to clean and maintain. These are suitable for producing furniture components, but also for a wide range of other applications in decorative contract fittings.
At Toms Gerber GmbH, we manufacture postformed components for a wide range of applications and in a wide variety of designs. Thanks to our many years of experience with deploying and optimising this technology, we produce high-quality engineered-wood components with a range of curves and in a number of standard and combination profiles. Depending on the customer’s requirements, we process moisture-resistant or fire-resistant substrate materials, which we typically provide with cylindrical, concave or convex curves.
Digital technology means that, from the time a customer initially contacts us to the dispatch of pre-assembled components, we are able to collect our customers’ data and use it in our production. A CAD–CAM system with an ERP link also ensures that technical and commercial processes are brought together effectively, enabling us to offer efficient solutions. If our customer’s interior design project is so customised that a final form has not yet been determined, we often develop a detailed prototype for our customers. This is then usually the starting point for subsequent (small-scale) serial production.
Visual and functional benefits of postformed components
Postforming technology makes it possible to create individual shapes and designs that fit perfectly into the desired location. The components can be customised and flexibly shaped to meet highly individual requirements. Rounded furniture gives rooms a soft and stylish appearance. Thanks to our wide range of decorations and colours, we can cater to almost every preference, ensuring our products align perfectly with the décors and styles of very different rooms.
Organic shapes in interior design have undergone many changes throughout history. Opulence and playfulness were still very popular in the Baroque period, while Art Nouveau and Art Deco were simpler and more geometric. However, the combination of round and oval shapes with clear lines is still very popular today. In recent years, curved furniture has made a comeback for home interiors, and curved furniture with rounded edges is even in demand for office furnishings, as it also minimises the risk of injury, there being no sharp edges or pointed corners to bump into.
Using furniture with rounded corners enables designers to create rooms with a harmonious atmosphere. People find round shapes more pleasing because, unlike right angles and smooth surfaces, they are found in nature: Hundertwasser and Biophilic Design send their regards. Organic curves can be used to avoid harsh interruptions and dead corners, creating a visual connection to the neighbouring room in an open-plan kitchen area with rounded cupboard fronts, for example.
The use of postforming technology not only gives furniture an elegant look and customised decoration, it also ensures good resistance to wear and moisture. The seamless design of the furniture components and features prevents liquids from penetrating the structure of the postformed component, and dust and dirt have no points to settle on. In contrast to furniture components produced using other technologies, postformed panels are also easier to maintain thanks to the seamless transition between the edge and the surface. Dirt can therefore be easily wiped off and bacteria have no chance to settle.
The use of high-quality materials in conjunction with the structure of the postformed parts also makes for robust, durable products. For this reason, the easy-care nature of these elements is complemented by high resistance to mechanical stress. This makes furniture components with postformed edges ideal for use in kitchen and bathroom furniture, hospital furnishings, laboratory equipment, reception and sales counters, as well as ship furniture. As fire is one of the greatest dangers on board ship, it goes without saying that postformed components that meet fire safety requirements are also in demand; we supply these too.
All of the postformed components we offer can in fact be manufactured to meet very different requirements on request; selecting the right substrate material is crucial here. Demand with regard to fire safety requirements ranges from flame-retardant postformed components to non-combustible postformed components and furniture with postformed rounding that will not swell or is completely moisture-resistant. So while postforming technology scores highly in shipbuilding thanks to its special design with water resistance and the flame-retardant nature of the material, other places such as public facilities have similar requirements. Functionality combines with an elegant appearance.
Postforming in summary
Postformed components are the perfect way to create unique pieces of furniture with rounded edges and customised shapes. They are suitable for interior design, especially in areas where hygiene and durability are important. Whether projects relate to public facilities, hotels, kitchens or in ship and van interiors, they benefit from a high level of durability and the potential for customisation.
Furniture components and interior fittings with postformed edges are an attractive choice for a variety of rooms, both complementing their surroundings and having functional potential. Delivering properties that meet specialised requirements, postformed components can be manufactured to comply with fire safety regulations or designed so as to withstand liquids.
The Toms Gerber GmbH team has been manufacturing high-quality postformed components for many years, and thanks to their technological expertise and extensive experience with deploying and optimising of this technology, they offer a wide-ranging portfolio of services. We would be happy to advise you in detail on the design and deployment of the perfect postformed component to round off your project in the truest sense of the phrase. Contact us to find out more about the potential of this technology.