Acrylic shower pans are primarily manufactured by heating large sheets of acrylic and stretching them onto a mold. While typically reinforced with other materials for strength and durability, this thermoforming process forms the base structure of the pan.
Here's a breakdown of the core process based on the provided information:
- Material Preparation: Large sheets of acrylic are prepared for the manufacturing process.
- Heating: These acrylic sheets are heated to a specific temperature, making the material pliable and easy to work with.
- Molding: The heated acrylic sheet is then stretched or vacuum-formed over a pre-designed mold that matches the desired shape and size of the shower pan.
- Forming the Shape: As the acrylic cools on the mold, it retains the precise shape of the pan, including the base, sides, and drain opening.
- Reinforcement: After the basic shape is formed, the acrylic structure is typically reinforced with other materials, such as fiberglass or resin composites, to add rigidity and support. This reinforcement prevents flexing and cracking under weight and stress during use.
This method allows for the efficient production of seamless, non-porous shower pans that are lightweight and easy to install compared to some traditional materials.
