Custom XPS Boards

Custom XPS boards for projects where a standard rectangle does not fit: curved surfaces, pipe enclosures and CNC-cut shapes made to the approved drawing. The coated XPS construction remains familiar, but framing, support, board thickness, fixing points, joints and waterproof details still need to be verified for the finished assembly. Standard production covers boards from 4 mm to 50 mm, with other dimensions reviewed against the order. Send a DXF, PDF or clear dimensioned sketch with the intended application and quantities. Cutting details are confirmed for approval before production rather than treating an unmarked drawing as final manufacturing data.

  • What can we fabricate?

    Custom fabrication changes the shape, not the need to design and seal the complete assembly. Choose the product route that matches your drawing and site conditions.

    • Curved boards: curved XPS backer boards are used for radius walls, columns, curved partitions and shaped wet-room details. Send the radius, arc length, board thickness and support arrangement.
    • Pipe boxing: XPS pipe boxing boards are prepared for soil pipes, concealed services and bathroom enclosure details, with access and fixing requirements considered in the layout.
    • Cut-to-drawing boards: our custom XPS backer board cut to drawing service covers CNC fabrication of non-standard dimensions and shapes.

    The standard board format is 1220 × 2440 mm, and standard thicknesses run from 4 mm to 50 mm. Custom formats can be evaluated within the confirmed manufacturing range before the cutting drawing is approved.

    What should your drawing include?

    Send a DXF, PDF or clear sketch with overall dimensions, thickness, radii, openings, quantities and the intended application. Mark which dimensions are fixed and which can be adjusted for production. Include the support arrangement and the locations of joints, fixings and penetrations where they affect fabrication.

    Applicable board products carry CE marking to EN 13164. ICC-ES PMG-1804 applies to the evaluated tileable shower system; it is not blanket approval for every custom shape or modified assembly. A custom component should therefore be checked against the applicable product scope, installation detail and local project requirements.

    See how shaped boards fit into real rooms on our Applications page.

    Frequently asked questions

    Which drawing formats can I send?

    DXF is suitable for CNC review, while a PDF or clear dimensioned sketch can be used to start the discussion. Every route needs readable dimensions, thickness, quantities and the intended application before a production drawing can be confirmed.

    What information does a curved board require?

    Provide the radius, arc length, chord or overall dimensions, board thickness, quantity and support arrangement. State whether the board forms a wall, seat, niche or another element, because the fixing and waterproofing details depend on that use.

    Does a custom shape automatically keep the same certification coverage?

    No. Certification coverage depends on the applicable document and product scope, not simply on using the same base material. Cutting, shaping or changing the assembly must be reviewed rather than presenting every custom component as automatically covered by ICC-ES PMG-1804.

    Send your drawing and project details through our custom fabrication contact form. We will review the required inputs and confirm the cutting details before manufacturing.