Shower base

EPS base serving as the structure for showers with a ceramic base.

Objective: Produce highly precise, high density grey EPS panels with multiple converging surfaces for a construction accessories client to facilitate tiles installation in ceramic showers.
Challenges:
- Design a surface on which the cement will stick with the help of mortise joints
- Insure the precise moulding of high density EPS on parts with many tilted surfaces and irregular profiles
- Insure the parts’ high dimensional and mechanical integrity
- Insure high productivity while respecting high standards of aesthetic and dimensional quality
- Insure a uniform and constant grey coloring
- Ship daily large quantities of dry, compliant and individually packaged pieces
Solutions:
- Design a modular mould able to produce precise pieces with sharps edges, converging surfaces and perfectly attached
- Manufacturing a high rigidity equipment that will insure the flatness of the high density EPS surfaces
- Highly efficient production by optimizing the mould’s thermodynamic efficiency, by minimizing its mass without reducing its mechanical resistance
- Implementing a faultless drying, assembly and quality control process
Result: The quality and precision of the EPS parts provided the ceramic shower installers a quick and efficient solution. Polymos’ client has relied on this quality to build his reputation and therefore surpass his North American commercial forecasts.