Our glass cutting process

The production of our panels takes time and skill, and combines cutting-edge technology with hands-on craftmanship and years of training and experience. From the precision of our cuts to the layering of our paint, every part of the process is done with care to a rigorous standard.

Although we do our best to produce panels as quickly as possible, we have extremely high standards of quality and will start from scratch if a finished piece does not meet our expectations. We also check and double check to ensure that no errors are made in the cutting and shaping of our splashbacks, and that the final result is a perfect fit. Furthermore, large sheets of glass must be handled with care, particularly before being toughened, so our staff observe strict safety protocols at all times and are trained not to rush!

We aim to produce our panels within 7 to 10 working days and nearly always meet this deadline. But for these reasons we cannot give a definitive date of delivery until the panels are finished and have passed our strict quality control requirements.

How our glass panels are made

Glass delivery

Large sheets of glass, weighing many tonnes, are delivered to our workshops and loaded onto racks. This dangerous and delicate operation is carried out by our skilled machine operators.

We refer to the detailed glass cutting measurement plans drawn up by our expert surveyors

Survey review

We refer to the detailed measurement plans drawn up by our expert surveyors.

CAD drawings

The panel dimensions are programmed into a computer, turned into CAD (computer-aided design) drawings, and sent to our water-jet cutting machines.

Scoring

To create the correct size of panel, large sheets of glass are scored by machine but broken out (snapped) by hand. This has to be done quickly before the glass “heals”.

The glass panel size is measured for any slight inaccuracies, which are then corrected by hand

Precision adjustments

The panel size is measured for any slight inaccuracies, which are then corrected by hand.

The outer edges of the glass splashback are polished by machine

Edge polishing

The outer edges of the glass are polished by machine. Because the glass sits upright in the machine, our maximum panel size is 3900mm – a 4000mm high panel would be too dangerous to process.

Using the CAD drawings produced earlier, cut-outs for sockets and switches are made using a high-pressure jet of water and sand to cut glass

Water-jet glass cutting

The panel is now ready to be moved to our water-jet glass cutting equipment. Using the CAD drawings produced earlier, cut-outs for sockets and switches are made using a high-pressure jet of water and sand. This cuts through glass with incredible accuracy.

Edge smoothing

The edges of the jetted glass are buffed to a smooth finish by hand.

Wash and inspection

The glass is washed and inspected for flaws, in accordance with our strict quality control guidelines.

Toughening

Each panel is labelled by job, rotation and position – some of our larger projects require up to 50 panels, which are fitted together like a jigsaw. The glass can now be toughened for heat and impact resistance.

Preparing the
paint or image

With the glass cut to size, and toughened, the panels are moved to our finishing studios for the next stage of the process – preparing the colour or printed image.

Colouring and printing

Once the colour has been finalised and the paint mixed, it is applied by hand to the back of the glass panels. Multiple layers and a skilful technique ensure a solid, even coating. Patterns and images are digitally applied using the latest printing technology.

All our glass panels are rigorously quality controlled by our trained craftsmen, and finished perfectly by hand

Finishing by hand

All our panels are rigorously quality controlled by our trained craftsmen, and finished perfectly by hand.

Following their final inspection, our glass panels are cleaned and buffed once again

Final clean and polish

Following their final inspection, our panels are cleaned and buffed once again.

When the glass panels have been cleared for delivery they are packaged securely

Secure packing

When the panels have been cleared for delivery they are packaged securely. If we are sending them by courier we fix them into crates for added protection.