Abstract: Provided is a method for producing stone inlay tesserae for forming a mosaic pattern surface, the method comprises the steps of: providing at least one core made from a natural stone material; providing a mold having an internal surface that defines an internal cavity for accommodating the at least one core, the internal cavity has a volume larger than that of the at least one core, such that an internal space is formed between the internal surface of the mold and the at least one core when the at least one core is placed within the mold; adding a molding composite into the mold to fill the internal space; solidifying the molding composite, thereby forming a hybrid tessera column comprising a stone inlay and an external layer seamlessly around the at least one core; demolding the hybrid tessera column from the mold; and cutting the hybrid tessera column into a plurality of stone inlay tesserae.

Abstract: A method of making a mechanically-held tile is disclosed by providing a tile having a durable surface, an underside and an anchoring region, locating the tile in a mold, and injecting a polymer into the mold to form a substrate with an integral coupling region. Alternatively, a substrate can be provided in addition to the tile; the injected material mechanically anchors the substrate to the tile. A surrounding grout gasket can also be formed during injection. Injections can be consecutive or concurrent to tailor the properties of the substrate, grout gasket and other layers or regions. Also disclosed is a multi-part tile made by such a process, and a tile with intrinsic manufacturing deviations compensated by a grout gasket. The tile can be interconnected via the coupling regions with other surface-covering materials.

Abstract: A method of making a mechanically-held tile is disclosed by providing a tile having a durable surface, an underside and an anchoring region, locating the tile in a mould, and injecting a polymer into the mould to form a substrate with an integral coupling region. Alternatively, a substrate can be provided in addition to the tile; the injected material mechanically anchors the substrate to the tile. A surrounding grout gasket can also be formed during injection. Injections can be consecutive or concurrent to tailor the properties of the substrate, grout gasket and other layers or regions. Also disclosed is a multi-part tile made by such a process, and a tile with intrinsic manufacturing deviations compensated by a grout gasket. The tile can be interconnected via the coupling regions with other surface-covering materials.