From Design Intent to Fabrication-Ready: How CASF’s Design Solutions Service Closes the Gap
CASF’s Design Solutions Service exists to close that gap. For architects and interior designers specifying Corian® Solid Surface, it provides shop drawings, photorealistic renders, and fabrication-ready documentation — prepared by CASF’s technical team at no charge, as part of the specification process.
The Boollam Boollam Aged Care Centre is one of the clearest demonstrations of what that service delivers in practice.
The project
ClarkeHopkinsClarke Architects were responsible for approximately 140 custom ensuite vanities and 20 integrated hand wash basins for the new 150-bed Monash Health facility in Cheltenham. The brief demanded AS1428.1-compliant accessible bathrooms, infection control performance to clinical governance standard, and a solution that could be fabricated and installed consistently at scale.
The design team specified a Corian® vanity with a fully integrated basin and storage in Glacier White — a single seamless unit with no junction between basin and bench, and a matte, low-reflectivity finish chosen specifically for residents with dementia or cognitive conditions.
It was an ambitious specification. Getting it right once would have been an achievement. Getting it right 150 times required a different approach.
Where the Design Solutions Service came in
CASF was engaged during detailed design — before documentation was finalised — to test whether the design intent could be practically realised at the required scale.
The process started with shop drawings: detailed fabrication drawings prepared by CASF’s technical team that translated the design intent into something a fabricator could build from. These drawings allowed the design team to review construction methodology, confirm accessibility clearances, and identify anything that needed refinement before production.
From there, the team moved to a full-scale prototype, installed in an off-site mock-up of a typical bedroom and ensuite. Tap placement was adjusted. Mounting methods were refined. Splash control was tested against the actual installed unit. Infection control compliance was verified in three dimensions, not on paper.
By the time the project went into production, the hard questions had already been answered. One hundred and fifty units, fabricated to a tight brief, consistently.
What this means for your specification
The value of early technical engagement isn’t unique to aged care or large-scale projects. It applies any time the gap between design intent and fabrication outcome carries risk — which is most of the time when Corian® is being used for something other than a standard benchtop.
Thermoformed elements. Integrated basins. Seamless feature walls. Reception counters with complex geometry. These are the applications where Corian® performs best, and where the distance between a concept and a buildable outcome is widest.
CASF’s Design Solutions Service is structured to cover that distance. Shop drawings produced by CASF’s technical team give fabricators exactly what they need. Photorealistic renders let designers and clients confirm the outcome before anything is cut. Fabrication-ready documentation means the project moves from design to production without the back-and-forth that adds time and risk.
And it’s provided at no charge — because helping architects and designers get the specification right is how CASF does its best work.