Custom Countertop Design Software for Lab-Grade Epoxy Surfaces

Client Name
USA Based Client

  • Technologies

    C#, Windows Forms (WinForms), Eyeshot, Infragistics

  • Domain

    Engineering and Manufacturing

Client Overview

Our client, located in the USA, makes tough, high-quality epoxy resin countertops and sinks. These products are built to handle harsh chemicals, heat, and everyday wear and tear, making them a top choice for schools, universities, labs, and industrial buildings.

Project Overview

Our client wanted an easy way to design and customize lab countertops and sinks. They needed a tool that could help plan and build tabletop structures for labs, whether designing an entire room or just a single piece. At ProtoTech Solutions, we built a custom application that makes this process simple and efficient. Design full room layouts, which automatically break down into individual pieces, or create and customize single pieces on their own. Users can either:

  • Easy design options at both the room and piece levels
  • Support for over 100 types of cutouts and edge styles
  • Barcode-based tracking during production
  • Direct integration with machines to generate toolpaths for manufacturing

This solution helps streamline lab surface planning and ensures everything fits perfectly from design to production.

Challenges

  • Support for multiple piece types (Flat, Custom, Marine Edge, Fumehood)
  • Handle custom properties linked to geometry
  • Create pieces based on room layout and interactions
  • Manage complex cutouts (notches, angles, curves) with pattern support
  • Apply parietal finish edges to lines and curves
  • Automate ticket creation for each room’s production
  • Show vector view from .eye files in ticket drawings using Eyshot
  • Display barcodes on sheets to pull up user info when scanned

Cutout Challenges:

  • Detect cutouts accurately in layout shapes (e.g., U-shapes, joints)
  • Classify cutouts by type: notch, hole, angled cut
  • Treat cutouts as editable piece-level features
  • Create a single UI for internal, perimeter, and pattern cutouts

Modular Assembly Challenges:

  • Join modular pieces like countertops or benches correctly
  • Fix edge profile mismatches (e.g., BVL vs BDG), causing errors
  • Handle visual misalignment due to rotation (e.g., 0° vs 90°)
  • Accurately apply toolpaths at mid-edge joins or connection points

Solutions

  • Let users create different piece types with custom options.
  • Built custom objects in Eyeshot to store extra piece info and save/load it easily.
  • Switched to using blocks (not sketches) for room layouts for more flexibility.
  • Made a tool to import 2D DWG files with support for 100+ cutout types.
  • Added features to split edges, add new ones, and keep them in order.
  • Calculated and stored tool vertex and patch info based on client feedback.
  • Used Eyeshot tools to keep cutout shapes stable when edited.
  • Added support for pattern cutouts in the cutout tool.

Built a ticket system using Eyeshot for printing and PDF export:

  • Rebuilt the sheet to properly show the design view.
  • Used text (not image) for barcode so it scans correctly.

Improved cutout handling:

  • Used shape-tracking to detect voids and subtract areas.
  • Tagged cutouts as inside or on the edge based on their position.
  • Make sure cutouts are only placed in allowed zones.
  • Made cutouts editable and movable with type switching (e.g., rectangle to notch).
  • Saved all cutout info (shape, size, position, ID, etc.) to the database.

Built an adjoining system to manage how pieces connect:

  • Validated edge profiles for accurate joining.
  • Prevented multiple joins on the same edge.
  • Tracked rotation, offset, and alignment of joins.
  • Saved connection point data for mid-edge joins and future features.
  • Used unique IDs for each edge for easy tracking.
  • Made each piece aware of its edges, position, and rotation.

Benefits

  • More Customization: Made it easier to design and adjust countertop pieces just the way you want.
  • Better Accuracy: Automated toolpaths helped reduce mistakes during manufacturing.
  • Faster Process: Cut down on manual work for handling cutouts and creating tickets.
  • Smooth Workflow: Digital automation made the whole production process more seamless.
  • Easy to Scale: Flexible system that grows with your design and manufacturing needs.

Testimonial

“Before we had this custom software, designing countertops was a slow, manual process, and mistakes were common. Now, everything’s faster, more accurate, and just makes sense. The interface is easy to use, the cutout features are incredibly flexible, and the integration with our manufacturing systems is seamless. We've seen a major boost in accuracy and productivity. I highly recommend working with this team!"

John D.

Operations Manager

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