At Syn-Mar Products, we believe in a practical, no-nonsense approach to manufacturing high-quality, grout-free shower systems for your home. Founded in 1977 and based in Ellington, CT, we engineer custom products that eliminate grime and make maintaining a clean bathroom effortless. Recently, we showcased our casting department to reveal exactly how our custom shower walls and custom shower bases are made.

The Casting Process: Steps to Perfection

Because we control every step of the manufacturing process in-house, we ensure consistent, beautiful results. Tom, our production supervisor of seven years, emphasizes the precision required: 

To truly appreciate the quality of a grout-free shower system, you have to look at how it is made. Here is a breakdown of our exact casting process:

• Step 1: Organizing Raw Materials. Precision starts before a single product is poured. We carefully separate dry ingredients from wet ingredients in our receiving area. To ensure absolute accuracy during batching, our resin is piped directly through the wall from our dedicated resin room straight to our industrial scales.

• Step 2: Precision Batching & Mixing. Every color and finish has a specific recipe. We use precise formulas and procedures to ensure color consistency from batch to batch. Based on these formulas, we mix our resins, pigments, and stone fillers to a consistency that is easy to mix and hand-cast onto the molds.

• Step 3: Timing the Catalyst. Once the base materials are fully mixed, we add a catalyst. From here, the clock starts ticking and every minute counts. It's important to get the mix cast onto the molds within 10-15 minutes. If there are any delays, the entire curing process could be ruined.

• Step 3: Casting and Vibrating. After the material is poured into our custom shower base and wall molds, it is vigorously vibrated. This is arguably the most important part of the casting process. Vibrating the molds for 10 to 12 minutes forces all trapped air bubbles to escape, ensuring a dense, structurally sound panel.

• Step 4: Curing and Demolding. Once casting and vibrating are complete, the molds are then moved to our setup area to fully cure. From here they are demolded and transferred to the finishing department.

Quality You Can Trust, Delivered Directly

Because we control the manufacturing process from raw material to finished product, we maintain strict quality control. Unlike competitors who rely on middle-man distribution companies, we sell direct to our dealer partners and deliver directly to their business locations on our own trucks. This ensures your custom shower bases and walls arrive safely and on time.

We proudly stand firmly behind our craftsmanship, offering a 5-year warranty on all our manufactured products. 

Complete the Look: Seamless Vanity Tops

While the shower is the centerpiece, no bathroom remodel is complete without updating the vanity area. To perfectly complement the clean lines of your new shower walls, we also manufacture beautiful, seamless vanity tops. Crafted as one solid piece with the sink integrated directly into the design, these tops eliminate the crevices where water and grime hide.

Whether you are doing a quick update or a total bathroom overhaul, choosing the right materials makes all the difference. Connect with a premium dealer showroom today to start designing your custom, grout-free oasis.

Frequently Asked Questions

Ready for a Beautiful, Grout-Free Bathroom?

Syn-Mar products are supplied exclusively through our trusted network of B2B dealer partners. If you are a homeowner looking to upgrade your space with White Onyx, connect with an authorized dealer today.