Photo-Engraving

Manufacturing process

01

A photo or graphic serves as the model for the master mold. They are converted into a file with 256 shades of gray on a computer. Each degree of gray defines a groove width. The CNC-cutter transfers the digital model onto board material.

02

The milling cast is sealed with a release wax and provided with a forming frame. Subsequently, a liquid elastomer is poured onto the cast to produce the formliner.

03

After the synthetic solidifies, the forming frame can be removed. The high elasticity of the formliner enables a reproduction of the pattern that is true to detail and makes it robust enough to be reused multiple times (up to 100 times).

04

The formliner is glued to the mold and waxed with release agents before the concrete is cast.

05

The formliner can be used at the precast plant and in the in-situ concrete.

06

After the concrete has hardened, the element can be removed with no problem. The formliner is ready to use again, up to 100 times depending on the type.

References

Störtebeker Elbphilharmonie, Hamburg, Photo-Engraving
Edison Residence, Montreal, Photo-Engraving
Kindergarten Barcelona, Fotogravur
Ovata building, Foto-gravur
University Paul Sabatier, Photo-engraving