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resin or other material for sink?

I'd like to try making my own bathroom sink, and I'm wondering what sort of material(s) would resist cracking / chipping / discoloration, and preferably not be poisonous.  

My first thought was some sort of cast resin.  Googling "cast resin sinks" will turn up a ton of cool looking products.  Bonus is being able to light it up from the inside.  I'm not sure what sort of resin is used for those products, though.

I also considered the "inverse":  sculpting a shape out of wood etc., then layering it with something like Aquaresin with fiberglass reinforcement, and polishing.  Might not be a tough enough surface, but perhaps could be sealed with an epoxy / urethane / what have you.

I'm not sure that going fired clay will give me the modern / futuristic look I'm going for... Unless there's a way to have someone apply a glossy ceramic coating to a piece that you bring in.

Concrete was considered and discarded - mostly for aesthetic reasons, but also weight.  Really, resin seems the easiest route - but still looking for input from any materials experts out there.

I have tried different casting with different sorts of resin and they all one thing in common : in big quantities the stuff tends to shrink a lot when curing.

Also it is very pricey.

A good alternative, except for the finnishing coat could be surf repair resin.

The stuff is quite cheap and cures with UV light, so you do your work inside and with time and simply put in the sun for a few hours to get it hard.

Final coat with some epoxy or poleurethane varnish, epoxy floor sealer worked well for me although it takes 3 days to fully cure and another week to stop smelling.
But give a very scratch resistant surface.

If you need glass clear material only castin resin is an option and you have to do in many layers doe to the shrinking.

Another way would be to make a plaster cast first and to use the vacuum shrink method to fix a sheet of clear acrylic or perspex on it - this will be the outer surface of the finished sink.
Coat it with several layers of clear resin or fill it up, depending on your needs.

If you add lights that touch the plastic and fill the rest with fibreglass you will still get a nice illuminated finnish, just put the lights in an even spacing.

There are more ways and ideas that pop into mind, but I'm sure others want to contribute some more too ;)

meeotch (author)  Downunder35m2 years ago

Awesome, reply - thanks! w.r.t. resins: absolute transparency isn't necessarily a requirement. Particularly if I light it, I'd want the light to diffuse within the material.

I'd be more concerned with toxicity, durability of the surface, etc. I guess shrinkage wouldn't be a huge issue if I'm not concerned with final size & can drill holes for a faucet, support, etc. afterwards. Cracking due to volume would obviously not be so easily dismissed.

Some cool reference for wild shapes: https://www.google.com/search?q=modern+sink&source...

And resin specifically: https://www.google.com/search?q=modern+sink&source...

Again, thanks - and if other people have ideas to add, keep 'em coming!