Commercial Millwork Company That Works With Multiple Materials | AF Johnson

In this episode of The Maker’s Intent, host Mike Downer sits down with Kyle Greenfield, president and owner of AF Johnson Millwork Company, to explore what it really takes to bond wood, steel, resin, and stone in commercial fabrication. The discussion goes beyond adhesives and into the realities of engineering, structure, environmental movement, and installation. For anyone curious about how a commercial millwork company that works with multiple materials approaches complex builds, this conversation offers a practical look behind the finished product.

From the start, Kyle makes it clear that success in multi-material fabrication depends on more than making materials stick together. The biggest takeaways are woven through the conversation: gravity changes everything, structural support matters as much as bonding, different materials move in different ways, and testing in controlled conditions can prevent expensive surprises in the field. The result is a reminder that beautiful commercial millwork is often the product of hidden engineering and years of hard-earned experience.

Why Gravity Is One of the First Design Considerations

One of Kyle’s most useful insights is also one of the simplest. When asked how AF Johnson Millwork Company bonds different materials together, he explains that “it kind of depends on whether gravity is helping us.” That distinction shapes the entire fabrication strategy.

For horizontal applications like tabletops, desktops, and bar tops, gravity naturally helps keep materials seated in place. In some situations, a bonding agent as simple as silicone can be enough because the material is already being pressed downward and is less likely to shift. These projects still require care, but they begin with a major advantage.

Vertical applications are another story. Once a material is hanging on a wall, mounted off the side of a desk, or floating away from a structure, gravity becomes part of the challenge. In those cases, adhesive alone is rarely the full answer. The piece may need hidden metal bolts, steel reinforcement, or other concealed support systems that preserve the visual design while carrying the load safely.

The Real Challenge of Bonding Wood and Steel

When the conversation turns to wood and steel, Kyle points to two main concerns: weight and mounting. In commercial fabrication, the question is not only whether wood can attach to steel, but whether the final assembly can be supported by the surrounding structure.

That issue becomes even more important in today’s design environment, where floating shelves, stand-off wall elements, and minimalist architectural details are in high demand. These features often need to look clean and effortless, with no visible brackets or fasteners. But behind that appearance is a significant amount of engineering.

To make those designs work, AF Johnson Millwork Company often has to evaluate the existing structure, understand how the wall is built, and determine whether the building can support the intended load. In many cases, the challenge is less about bonding two materials and more about integrating them into a larger system that remains safe, durable, and visually precise.

Resin Looks Easy Online, but It Rarely Is

Resin and epoxy features have become increasingly popular, especially in statement pieces like bar tops and river tables. Kyle notes that full resin applications can be more straightforward because the surface is sealed consistently and tends to react as one material.

The real complexity shows up when resin is combined with natural wood. A river table may look seamless when it is first completed, but the materials are behaving very differently over time. Once resin cures, it becomes relatively stable. Wood does not. Wood continues to react to humidity and temperature, and it can shrink, swell, twist, or warp.

That difference in movement is what makes these projects so demanding. The challenge is not just creating a clean pour. It is stabilizing the wood so that it behaves more predictably and does not pull away from the resin or distort the final piece later. As Kyle suggests, the hard part is often not the resin itself but getting the wood to cooperate with it long-term.

Stone and Wood Demand Early Structural Planning

The conversation also highlights the structural demands of combining stone and wood. Stone may create a rich, premium look, but it also introduces significant weight. That means support requirements have to be considered early in the design process, not after fabrication is underway.

For horizontal applications, the team may need extra support underneath the stone so the load does not cause failure over time. For vertical installations, the concerns grow even larger. Commercial walls are often framed with thin-gauge metal, which may not be capable of carrying heavy decorative materials without reinforcement.

In those situations, AF Johnson Millwork Company may need to coordinate with contractors or owners to strengthen the building structure before installation. That kind of early planning protects the project and helps ensure that the design intent can actually be built.

Why Testing and Prototyping Matter So Much

Another major theme in the interview is the value of assembling projects in the shop before they ever go to the field. Kyle explains that AF Johnson Millwork Company prefers to put everything together in the plant first as a quality control measure.

That process serves several purposes. First, it confirms that the product looks and functions as intended. Second, it provides a clear baseline if something shifts during shipping or installation. If the team knows the assembly worked in the shop, they can more quickly diagnose what changed later.

Just as importantly, the plant offers controlled conditions. Temperature and moisture can be managed there in ways they cannot on an active construction site. That matters because different materials react differently to heat, humidity, and environmental fluctuation. Testing in the shop reduces uncertainty and improves consistency.

Why Many Shops Avoid Multi-Material Work

Kyle offers a candid answer when asked why many fabrication shops shy away from multi-material projects. In his view, it comes down to experience. Many companies simply are not comfortable working across several trades at once.

AF Johnson Millwork Company has an advantage because it has been around since the 1930s and has likely seen many versions of these challenges before. The company also works with long-term partners in metal fabrication, stone, and lighting, which allows it to bring in the right expertise when needed.

That experience gives designers and clients something valuable: a one-stop solution. Instead of coordinating several separate vendors and hoping they align, they can work with one team that understands how the parts fit together.

A Hospital Lobby That Brought It All Together

One of the most memorable examples Kyle shares is a curved hospital entry lobby. The wall panels had to follow a tall curved surface, but the acrylic directional signs were flat and could not bend. That created a difficult coordination problem.

AF Johnson Millwork Company solved it by building a temporary wall in the shop and test-fitting the entire system before installation. The team mounted curved laminate panels, aligned the acrylic signs, set hidden anchors, and worked through the tolerances in advance. Only after proving the solution in the shop did they take it apart and reassemble it on-site, two stories in the air.

It is a great example of what separates successful custom fabrication from surface-level craftsmanship. The final result may look effortless, but it is built on planning, mockups, and trial and error.

At the heart of this conversation is a simple truth: exceptional commercial fabrication is never just about appearance. It is about making ambitious designs work in the real world through engineering, testing, and collaboration. That is what sets apart a commercial millwork company that works with multiple materials.

FAQs

What is the biggest challenge in bonding multiple materials?

The biggest challenge is understanding how each material behaves over time. Weight, gravity, humidity, temperature, and movement all affect whether a finished piece will stay stable.

Why is gravity so important in fabrication?

Gravity influences whether a material is naturally supported or actively pulling against the installation. Horizontal pieces often benefit from gravity, while vertical and floating elements need more structural help.

Why is wood difficult to combine with resin?

Wood keeps moving as environmental conditions change, while cured resin remains more stable. That mismatch can create stress, separation, or warping if the wood is not properly stabilized.

Why does prototyping matter for commercial millwork?

Prototyping helps teams confirm fit, alignment, and performance in controlled conditions before facing the unpredictability of a job site.

Why do some shops avoid multi-material projects?

Many avoid them because they require cross-disciplinary knowledge, more engineering, and tighter coordination than standard fabrication work.