The Overall Process Flow (12 Stages)
- Taking the customer survey + analysing requirements
- Slab selection (type, colour, pattern, thickness)
- CAD drawing — the countertop dimension file
- CAM program — the cutting path + edge profile
- Placing the slab on the table + securing it
- Straight contour cutting
- Sink cut-out + hob cut-out
- Machining the edge profile (ogee, bullnose, V-cut and so on)
- Polishing + buffing (manual or semi-automatic)
- Quality control (dimensions + surface)
- Packing + loading
- Delivery to site + installation
1. Taking the Customer Survey
Wrong dimensions = a wasted countertop = a lost customer. Professional standards for taking the survey:
- A laser distance meter (accuracy of at least ±2 mm)
- Corner angles — walls are rarely a true 90° (a 3-5° deviation is common)
- Making a template — mandatory on a complex countertop (aluminium profile or foam)
- Sink + hob position — the cut-out dimensions differ by brand (check the installation guide)
- Additional connection points — the line of the wall cabinets, any clash with a drawer
- The datum level (height reference) — any slope in the floor must be noted
- Photographs + video — a reference for any doubt back in the workshop
The Classic Mistake
The customer says "the sink cut-out in the middle" but which point is "the middle" was never settled in the CAD — a 5-10 mm offset often results. Always confirm with a template or a photograph.
2. Slab Selection
- Type: marble, granite, travertine, onyx, engineered stone (Silestone, Caesarstone, Quartz)
- Thickness: 20 mm (standard), 30 mm (premium), 40 mm (luxury / island)
- Colour + pattern: chosen with the customer item by item (at the workshop or the marble yard)
- Slab size: on average 3000 × 2000 mm (marble), 3200 × 1600 mm (engineered stone)
- Colour matching: selecting from the same block is essential (the difference in tone between blocks is marked)
- Defect check: cracks, porosity, tone distribution — a buyer's signature is advisable
3. CAD Drawing
The CAD file is the source of the cutting instruction. Common software: AutoCAD, Rhino, SolidWorks, sector-specific CAD (StoneCAD, MarbleCAD).
- The main contour — the outer boundary of the countertop
- The sink cut-out — offset to the brand's cut-out dimensions
- The hob cut-out — to the size of the gas or electric hob
- Edge profile drawing — which profile on which edge (by symbol or hatching)
- V-cut lines, decorative patterning — where present
- DXF or DWG output — for CAM
4. The CAM Program
The CAD file is transferred into the CAM software, where the cutting path + tool selection + parameters are set. Common CAM packages for CNC bridge machines: TEX Computer (the USEL standard), Fagor, Alphacam and the CNC versions of MasterCAM.
- Cutting order — from small detail to large (for accuracy)
- The pierce (entry) point — place it where it will not be seen
- Blade selection — mesh, diameter, segments
- Cutting speed — from the table, by material + thickness
- Cooling water — flow rate + nozzle direction
- Multiple passes — for thick work (30-50 mm of depth per pass)
- Optimisation — idle travel is minimised
- Simulation — collision checking in the CAM (critical on 5 axis)
5. Securing the Slab
- Vacuum table — fast and suited to large slabs (the modern standard)
- Mechanical clamps — for small pieces or where vacuum will not hold
- Template logic — for repeat production on the same slab type
- Support under the slab — extra bearing for thick work + heavy slabs (40 mm+)
- Checking the hold — every point is tested before cutting
A Workholding Failure
Inadequate workholding = the slab being thrown clear during cutting = damage to the machine and the operator. Workholding is NEVER skipped.
6. Contour Cutting
Standard cutting parameters (30 mm marble):
- Blade: 400 mm diameter, #50-60 mesh, medium bond, 24 segments
- Speed: 2,500-3,000 rpm
- Feed: 1,500-2,500 mm/min
- Cutting depth: a single pass (30 mm)
- Cooling: 25 L/min flow
- Standard time: a 2.5 m contour takes ~3-5 minutes
7. The Sink and Hob Cut-Outs
The sink cut-out requires an internal edge profile — it takes time after the cutting:
- The pierce point — in a corner of the cut-out that will not be seen (beneath the slope)
- Internal contour cutting — at slow speed (risk of kick-back)
- Corner radius — mind the blade radius (at least 12 mm)
- The internal edge profile (5 axis) — softened with a milling tool
- The edge under the countertop (which will not be seen) can be left plain
8. Machining the Edge Profile
4 Axis — Manual Polishing
- It comes off the cut rough
- Manual transfer to the polishing machine
- The operator works it on the profiling machine
- Time: 15-25 min per countertop
- Accuracy: depends on operator skill
- Hard to standardise
5 Axis — A Single Setup
- Cutting + profiling on the same machine
- The profile is machined with a milling tool (ogee, bullnose, V-cut)
- Time: 5-10 min per countertop
- Accuracy: a consistent ±0.1 mm
- Easy to standardise (the same program)
- Final manual polishing: the last buffing only
9. Polishing + Buffing
- Stage 1: 60 grit (coarse)
- Stage 2: 100 grit
- Stage 3: 200 grit
- Stage 4: 400 grit
- Stage 5: 800 grit
- Stage 6: 1500 grit
- Stage 7: polishing powder (the final buffing)
- 6-7 stages are enough for marble, 8-10 stages for granite
- A semi-automatic polishing machine — 3-5 times faster than manual work
10. Quality Control
- Dimensional check — with the template or a laser distance meter (±1 mm tolerance)
- Corner angles — with a square or an angle gauge
- Surface check — inspecting for cracks and porosity with a magnifier
- Polish quality — a reflection test (even under a light)
- Sink cut-out fit — confirmed with the template before installation
- Certification and labelling (for premium work)
11. Packing + Loading
- EVA foam covering (protects the polished faces)
- Corner protectors (foam or card)
- Stretch film (dust + moisture)
- A timber pallet or an A-frame (for transport)
- Loading: forklift or crane + safety strap
- Driver briefing: secured in the vehicle, gentle braking
12. Delivery to Site + Installation
- A delivery appointment with the customer
- Site check — cabinet alignment, wall flatness
- Setting the countertop onto the cabinet — with timber battens or silicone
- Fitting the sink + hob
- The joint line — keeping the whole consistent (marble mastic or an invisible adhesive)
- Care instructions for the customer — daily cleaning, annual buffing
- Getting the acceptance document signed
Typical Timings
| Stage | 4 Axis Workshop | 5 Axis Workshop |
|---|---|---|
| Customer survey + CAD | 40-60 min | 40-60 min |
| Cutting + sink | 15 min | 15 min |
| Edge profile | 20-25 min (manual) | 5-10 min (CNC) |
| Polishing | 15-20 min | 8-12 min |
| Quality + packing | 10 min | 10 min |
| WORKSHOP TOTAL | ~95-110 min | ~75-95 min |
| Site delivery + installation | 60-90 min | 60-90 min |
The Productivity Difference
A 5 axis workshop gains around 20 min per countertop. 60 countertops a month × 20 min = 20 hours of additional production capacity.