Creating the ideal work surface

Aug 13, 2025 | Industry Advice

Various tops for cutting mats

Various tops for cutting mats

As important as it is to make sure you have the most suitable equipment for any job, so too is the surface you work from. Making sure you have the correct workbench top and size could make working on any project that much easier, as Paul Hughes, owner of Sign Making Tools, explains.

A lot of time as sign makers is spent preparing prints or graphics for fitting, which can require considerable time on the workbench.

A good workbench is invaluable; the bigger the better for most jobs. There is nothing worse than trying to work large banners/prints/graphics on a workbench that is way too small. Space in the workshop always tends to be at a premium, but you will never regret having bigger benches; they will make your life so much easier and more efficient.

Workbenches can be purchased from many places or can, with basic skills, be constructed in-house. If building in-house, consider making multiple benches and fitting wheels to them so they can be moved around the workshop and configured in different ways to suit different jobs. For example, three 8x4ft benches can make one 4x24ft bench, great for long banners or an 8x12ft bench for constructing sign boards. Flexibility is key, the benches need to be all the same height and have brakes on the wheels; there is nothing worse than a bench wandering off as you push or pull against the job.

Height

What height should the bench be? Depends on how you plan to work at it; are you mainly going to be sitting on a chair or standing over it? The right height can make a big difference to how your back feels at the end of a working day, so maybe consider adjustable heights.

Surface

One of the main considerations should be what surface is the top of the bench to be? There are many different surfaces available, and which is right for you will depend somewhat on what jobs you want to do on the benches. Let’s have a look at some of the most commonly used materials:

Cutting mats come in all shapes and sizes. Most know the common green self-healing mats, which are very good, but tend to only be available in what is reality, for sign makers, small paper sizes; A0 and smaller. The smaller mats can be joined together, but this can lead to your knife tracing into the joint, which can be frustrating.

Larger mats are now available off the roll, which tend to be about 5mm thick and are commonly used on application tables/ flat bed laminators. The big advantage of this type of mat is that most benches can be covered in one piece without the need for any joints. These mats also have self-healing properties, which stop your knife from tracing into previous cuts. It should be noted that no mat is really self-healing, but has a surface that stops blades from running in previous cuts.

Off the roll mats

The mats of the roll also tend to be clear, which means prints with grids or set dimensions of common jobs can be placed under them to speed workflow. This type of mat is great for detailed cutting with scalpels and 9mm knives; not so good for cutting with heavy-duty 18mm knives, as they can cut deep into the material if care is not taken.

A 5mm piece of toughened glass can make a hard-wearing surface, but has the disadvantage that it can damage/wear the tips of blades.

High-Density Polyethylene (HDPE) or Polypropylene. These materials are chosen for their durability, resistance to chemicals, water, and wear and tear, as well as their ease of cleaning. This is the same material that kitchen chopping boards are made from.

Foamex can make a cost-effective surface, but over time will cut up and release debris, which can cause issues when trying to apply vinyl to boards. Static can also be an issue.

Plywood is a hard-wearing material if you are doing mainly construction-type work, but it will degrade and create debris if you regularly cut on it with knives.

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