It is no surprise to tell you that cutting solid-surface is harder for many people. It is because solid surface material contains a lot of mineral content. We are not talking about a solid plastic material. Solid-surface material such as Corian has a mineral bauxite derivative. The majority of the content is bauxite and the rest is polyester or acrylic resins.

When it comes to cutting solid-surface material, you need a new blade. If you don’t have a new blade, you can use the older one but make sure you have sharpened it. We recommend using protective gear while cutting Corian. Although the sawdust is not harmful as it is from the wooden material like cedar, yet, it is important to use protective gear.

Required Tools and Equipment

Cutting Corian requires you to acquire some tools and equipment. Without them, you can’t cut Corian easily. You need a marker, circular saw that has a 40-tooth blade, straightedge, woodworking clamps, straight cut fence, respirator, and eye protection goggles. Also, you need masking tape and solid-surface material sheets.

How to cut Corian – Step by Step Procedure

To cut Corian, you need to follow the steps given below.

Step 1:

It is not easy to cut solid-surface material. Indeed, it is a difficult procedure, particularly, if you opt to cut in with a simple circular saw. When using a circular saw, it is not easy to keep the blade of the tool on the material and run it straight through the material while cutting.

So, you must clamp a straight-cut guide on the sheet of the solid-surface to guide the circular saw foot. Yes, you can clap a straight 2×4 to the sheet that serves as a fence, keep in mind that it is critical to make cuts straight. The purpose is to ensure a perfect seam while joining the pieces.

Therefore, the first step is to draw or mark a cutting line on the material, lay the strip of masking tape over the solid-surface material to reduce the risk of chipping. Then, you need to mark a cutting line onto tape.

Doing so, you need to clamp your straight-cut guide fence to the sheet of the material. We recommend using spring clamps because they are good for securing a straight cut guide to the Corian Sheet.

Step 2:

Before you cut, you need to adjust the straight-cut fence so that the blade runs precisely on the marked cutting line. Likewise, you need to confirm the width of the fence. You can do this by lowering the depth of the blade as well as rotate the blade.

Once you have unplugged the tool, you must slide the saw gently down the length of the fence. Make sure you watch the alignment of the blade with the marked cutting line. Similarly, you need to create a support for the portion that has been cut-off of the sheet. This allows you to protect the sheet and don’t tear it out at the end.

Step 3:

It is now time to cut the Corian Material. First, you need to set the depth of the blade about 1/8 inches deeper compared to the Corian material thickness. Then, you plug in the saw and start cutting. Make sure the speed of the saw is a bit slower at the start. For example, people use a slow speed to cut the wood material. However, for Corian, the speed is even slower.

Make sure you keep the saw steady. Continue to move ahead slowly and steadily. You cannot overemphasize the need for patience and slowness. It is because Corian is a hard material and requires patience and careful work when it comes to cutting it. Similarly, you must not pause while cutting the Corian material. It is because the edges of Corian may scorch due to friction with the saw blade.

Important Considerations

Many experts suggest using different circular-motion saws to get straight cuts where the pieces of the material can seam together. However, it is important to know that these kinds of saws don’t work well to make the cutouts for countertop parts such as sinks.

If you are carrying out a DIY project, you need a rotary tool with a straight cutting bit, which you can use to make cutouts. You can make multiple passes using this tool while increasing the depth of each cut gradually so that you can penetrate the Corian easily.

So much so, you can cut out using a jigsaw. Usually, experts don’t recommend this tool for straight cuts, on the other hand, it works well for sink cutouts where you need to hide the rough edges by the sink flange.

Following the steps given above, you can cut the solid-surface material like Corian easily and effectively. Make sure you have all the equipment and tools available to get the job done accurately.

What’s the best way to cut Corian?

You can use a fine-tooth circular saw to cut Corian, a carbide blade with 80 to 100 teeth being ideal. If you have fewer teeth (for example, a standard 40-tooth blade), use masking tape on the Corian to reduce splintering.

Can you cut Corian with a jigsaw?

Finally, some DIYers have good luck making cutouts with a jigsaw. While this tool is never recommended for straight cuts that will be seamed, a jigsaw can work well enough for making sink cutouts where the rough edges will be hidden by the sink flange.

Can Corian be cut on site?

Unlike granite and similar materials, you can actually cut Corian with just about any tool that cuts through wood. This makes it considerably less dangerous to cut Corian than countertops made with other materials.

Can you use a router on Corian?

A router with carbide-tipped bits is also an excellent tool for making either straight or curved cuts in Corian, or for shaping edges. Techniques for using routers are discussed at some length in “How to Work With Corian.” Safety glasses or a face mask should always be worn when cutting Corian.

What tool do you use to cut Corian?

Cutting the Corian to size is normally done with a circular saw. Any blade which will cut wood will probably work, but the best is a triple chip carbide blade.

How do you join and cut Corian?

How to Cut and Seam Corian Step By Step
  1. Draw Your Cuts. Once you’re safely ready to go, you can take your pen or marker and begin drawing your planned cuts.
  2. Check Your Alignment.
  3. Secure Fences and Clamps.
  4. Carefully Cut.
  5. Wipe and Clean.
  6. Apply Support Strips.
  7. Apply Epoxy and Set.
  8. Sand and Buff.

What do you use to glue Corian together?

Corian is basically made of acrylic and polymer. The material is used a lot for countertops and vanities because of its beauty and durability. Epoxy glue can be used to make it stick together. You should always use a color-matching silicone to bind the countertops the cabinets and the back wall.

Can Corian be seamed?

When seaming two pieces of Corian® Solid Surface, it is important that the two pieces are a perfect fit. The quality of a seam is determined by how well the material fits together. The ideal preparation for two edges to be seamed is the router pull- through method (Mirror Cut).

How do you finish Corian edges?

Start by using 120-grit paper to sand away the cut in a tight circular pattern and then increase the sanding radius out to about 12”, spending more time toward the center. Next, sand the entire area with 180-grit paper, feathering out another 8” or more. Remember the color goes all the way through.

Can I use magic eraser on Corian?

To clean a Corian sink, use solutions with substances like vinegar, denture cleaners, ammonia, bleach, oxalic acid, baking soda, hydrogen peroxide, Viakal gel, and kitchen cleaners. Magic erasers are effective too.

Can you use Soft Scrub on Corian countertops?

NOTE: Do NOT use Soft Scrub on the countertop surface for everyday cleaning. Corian is heat resistant, but it is NOT safe to place hot pots and pans directly on the surface. Always use trivits or protective pads.

Is Corian dust dangerous?

The type of dust produced by fabricating Corian® surfaces is considered nontoxic and is referred to as nuisance dust. Inhalation of these nontoxic particles can cause irritation to the nose, throat and upper airways. There may be some odor due to small amounts of vapor being released during fabrication.

Can you put a hot pan on Corian?

While Corian® Solid Surface is heat resistant, as with all countertop materials, it is important to minimize direct heat exposure to protect your surface and investment. Important — Do not place hot pots, pans, etc. directly on the countertop surface.

Can you drill into Corian?

Corian® is drillable with standard drill bits and hole saws and is moderately difficult to break. However, you must be careful not to mar the surface when drilling.

How much is a sheet of Corian?

Fully Fabricated and Installed Estimates
Price Range Material Name Description
$2,196 to $3,050 Abalone Light, nearly pink creamy Corian with pale specks
$2,434 to $3,380 Lava Rock Dark and stone-like with bright speckles
$2,261 to $3,140 Burnt Amber Medium colored, busy patterned Corian emulating granite
Jul 15, 2020

Can I buy a sheet of Corian?

DuPont™ Corian® is one of the most versatile and respected solid surface material. Fabricated using standard woodworking tools, Corian sheets offer great “do it yourself” potential. Available in the standard sizes below with custom cuts available upon request.

Is Corian cheaper than granite?

Corian countertops vary widely in price, depending on the design and color. They begin at around $50 per square foot and range all the way up to $150. Sometimes Corian is cheaper than granite; sometimes it is more expensive. But as a general rule, it’s safe to say the two are comparable in price.