Custom XPS Backer Board Cut to Drawing – CNC Fabrication

Overview

Every job has that one board that does not exist: the wall-hung toilet panel with the cistern cut-out, the enclosure with three notches for three pipes, the arc that matches a curved counter. Site crews solve it with a jigsaw, a prayer, and an hour of dust. We solve it before the truck leaves — send the drawing and the board arrives cut, routed and ready to fix.
It is the same batch-tested coated board as the rest of the system: high-density XPS core, 0.8% water absorption over 96 hours, coated face that takes tile adhesive directly. The machining adds the geometry, the material adds nothing new to manage — one fixing pattern, one sealant, one tile spec, whatever the shape.
The workflow is built for contractors, not CAD operators. A PDF dimensioned sketch is enough to quote. We confirm the critical dimensions back with the quotation, cut and route against the confirmed drawing, and mark every board so the crew knows which wall it belongs to before the box is open.
Where it honestly stops: we cut the geometry, we do not design it. Dimensions on the drawing are the dimensions we cut, so the drawing needs to be right — measure twice on site, because we cut once in the factory. And structural members are out of scope: this is substrate, not structure.

Applications

Wall-hung toilet panels and concealed cistern walls
Pipe and service enclosures with cut-outs
Shaped substrates for prefab bathroom pods
Arcs, notches and shaped formwork panels

Fixing

On flat, sound backgrounds, bond or screw as with any board in the system. On uneven walls, our method pre-positions fixing points and anchors deep into the background so the board pulls flat before the first joint is sealed. Cut edges are coated faces too — seal them like any joint: elastic sealant, mesh tape, flood test before tiling.

See the full system: XPS Tile Backer Board 4-50mm >>