Updated: Apr 22, 2022
Your vision, just as every creation Fusion Flatworks, will be a labor of love, evolving creativity and very hard work. Let’s begin.
Step One: Secure Project Calendar Slot
Each burl wood table or countertop piece is unique, but we schedule a minimum of two months for any epoxy project. We match your timeline with our availability in our project calendar to ensure we give the dedication and priority each furniture piece deserves.
Step Two: Catch the Vision
Your one-of-a-kind heirloom epoxy wood functional work of art will surely be treasured for generations, so catching the vision is an integral part of the creative process. We begin by asking you questions, drawing the vision out of you so that our artists can dream up a way to realize it. Are you drawn to straight lines or curves, glamorous or natural, rich or light color? As we discuss your style, the purpose also becomes clear. Is your vision an entryway furniture piece that creates a sense of awe upon guests’ arrival? Or is it a live edge wood conference table that sets the stage for group inspiration. Perhaps we are creating a unique looking bar whose story you can feel with your fingertips, or a bedroom headboard so mysterious, no one can guess her origin.
Greg Dahl, Fusion Flatworks Lead Artisan
Step Three: Find the Perfect Piece of Burl Wood
Your treasure may be one we have onsite, cataloged and waiting patiently for it’s turn to be transformed into an unforgettable piece of functional art. Maybe the slab meant for this project is still waiting to be discovered, sourced by our own, “Burl Hunter,” unearthed by a land developer in northern Idaho, or dragged from a riverbed in Humbolt County, CA. Those “once in a lifetime” pieces are thrilling to hunt for and we love to adventure on your behalf. We abide by strict responsible harvesting practices which means the trees we choose to harvest must come down because they are required by law, deemed a nuisance, or because they are already dead or dying.
Step Four: Create the Blueprint
The project preparation varies, of course. A live edge river table requires first building a tightly sealed mold. An island table’s mold would be routed with a CNC machine. A slab takes years to dry out in nature, or six weeks in our kiln. Burl wood is particularly temperamental as it dries, some more than others. Madrone burl, for example, must be secured and clamped as it dries. Our Chief artisan says, “Train up a piece of wood in the way it should go and it will not depart from you.”
Step Five: Get to Work
Natural edges are sealed, epoxy is custom mixed and poured, sometimes in layers. After curing, surfaces are leveled again and sanded to desired grit that maximizes the desired look. Next, we CNC recesses and install hardware. Then, comes the finishing process which varies from a one-day process for a natural finish to a four-day process for glassy shine. The top quality epoxy we use takes 28 days to cure to perfect hardness, so we store and protect the project while we build a fortified crate for shipping.
Step Six: Document the Story
If you are choosing Fusion Flatworks to produce your project, then you value the uniqueness of the wood you chose, responsible harvesting, artistic journey, integrity in business, and the majesty of the finished product. We document the story of each as it unfolds for you to pass onto your children and your children’s children.
Step Seven: Over Deliver
With every functional work of art, our goal is to exceed your expectations.
“Fusion Flatworks is a wonderful team of hard working honest people. Their custom tables and projects are truly stunning! Greg the owner and Chris the sales manager are both so kind and genuine, it's been a pleasure doing business with them. I encourage you to check them out!”
"Greg and his team are very professional. They really listen to what you want and they deliver! It was wonderful working with them."