Toomer & Hayter sell sheets that look like wood veneer. We just got some to match our cherry flooring with holly inlay. Looks just like the real thing.
Builders merchant - but why are sheets of Formica (made in England) £50 here but about HK$80 (equal to about £5) after it's been shipped to Hong Kong. And it's not fake Formica!!
Maybe formica will make a comeback one day, like linoleum has! I remember when it was all the rage in the 70s , my dad covered every horizontal surface in our house enthusiastically with lovely phsycadelic colours. No I want smooth white if anyone has any spare. Black or yellow will look bit strange in the heads area.
I have sent email to Formica to find my nearest stockist.
Most of the Plastic Retailers, Trade or Wholesale will supply, Have a look in yellow pages for your local outlet. e.g. Ipswich Plastics... Do Formica or own brand in 8X4' sheets starting @ about £25.00. HTH
Have had the same problem as you until yesterday, I went into a small carpenters shop and they said have a look in their scrap area, which I did. Several offcuts of different colours and they gave me a 4 x 2 piece foc. they use it from time to time in shop / pub outfitting.
Having said that, for the heads try a double glazing manufacturer. Ask for a piece of infill panel, type of thing that forms the bottom solid panel of a door/conservatory. It's about an inch thick, shiny white plastic on both sides with foam insulation between. You can literally peel off the plastic sheets and then use a hot air gun and scraper to remove pieces of foam that remain attached to plastic.
Best way I found when cutting sheet formica is to use a hand tile cutter, or similar to score a deep groove on the shiny face of the formica. Then just break it. As long as the groove is deep enough you will get a nice clean edge.
If its not deep enough, the substrate will tend to break erratically leaving a rough edge which can easily be cleaned up with sandpaper or a file after. Practice on some offcuts first and you will soon get the hang of it.
Any saw is liable to shatter the surface laminate and give a rough edge. If the Formica is already glued down it can be cut with a fine tooth saw but be careful not to put too much pressure on the cutting edge as again it will cause shattering. Another way of avoiding that could be to try placing a piece of wood over the cut, and sawing right through it all, like when cutting plywood.
If you are using a jigsaw one with an oscillating blade that only cuts on the downstroke will give a much cleaner cut.
I cut it with a special laminate cutting blade (Stanley ref 5194B)for a Stanley Knife. You use it to score the laminate and then break it. If you carry on scoring you can actually cut right through.