Apparatus and method to manufacture shaped counter top edges for custom counter tops

A method to manufacture shaped counter top edges comprising the steps of:

• A. Providing a post form mold comprising a post form mold upper face, a post form lower face, and a post form mold shaping face, an edge of said post form upper face being disposed adjacent an edge of said post form mold shaping face, an edge of said post form lower face being disposed adjacent an edge of said post form mold shaping face opposite said post form upper face, a cross-sectional shape of said post form mold shaping face substantially corresponding to a shape desired to be given to a post formable sheet laminate;
• B. Providing a bonding fixture comprising at least one bonding press, each said bonding press comprising a pair of bonding press molds rotatably attached to a bonding press spine, each said bonding press mold comprising a bonding press mold face having a bonding press mold groove, a cross-sectional shape of said groove being substantially same as said shape desired to be given to said post formable sheet laminate, means of holding said bonding press molds such that their respective bonding press mold faces are substantially parallel and their bonding press mold grooves face each other and are substantially parallel with each other;
• C. Providing said post formable sheet laminate;
• D. Providing a substrate having at least one shaped edge whose cross-sectional shape is substantially same as said shape desired to be given to said post formable sheet laminate;
• E. Heating said laminate;
• F. Producing a formed laminate by clamping said laminate around said post form mold upper face, post form mold lower face, and post form mold shaping face;
• G. Removing said formed laminate from said post form mold;
• H. Applying adhesive to a formed laminate inside surface;
• I. Inserting said substrate shaped edge into said formed laminate;
• J. Inserting said substrate shaped edge covered by said formed laminate into one said bonding press mold groove;
• and
• K. Holding said bonding press closed on said formed laminate and substrate until said adhesive cures.