WatchHouse Coffee Countertops

With a design-led by Sarah Carpenter & Studio, we were tasked with fabricating countertops for the first WatchHouse Coffee location in New York City.

The mockup phase was essential in ensuring that the complex curvature could be achieved effectively. To begin, we utilized scrap materials for research and development, starting with the most complex aspect of the countertop, the front corner with compounding curvature. We drew out specific registration points on the solid surface sheets which were cut in a way that allowed them to form along custom molds we created. The sheets were thermoformed to ensure the geometry was correct, and then CNC trimmed for a perfect fit. Once we had successfully overcome the nuances of dialing in compound curvature, the rest of the process became more straightforward.

In terms of materiality — the project was initially planned to be made of stone but the team opted for a more affordable solid surface material from LG Himacs in an elegant almond color.

We also faced the challenge of minimizing the number of parts on-site while simultaneously needing them to fit through the front doors, so we pre-assembled the countertop in two parts in our shop. Once in the coffee shop, we seamed the two pieces on site.

The countertops and island, which featured a unique 'U' shape with an island in the middle, were crafted to be visually seamless. The attention to detail and dedication to quality were evident throughout the project, achieved through planning and testing of techniques to stay true to complex geometries.