Manufacturing Process

The production of US Formliner formliners follows a simple principle. Formliner patterns are inspired both by things we find in nature and things created digitally. Once we have the inspiration for a pattern, a positive cast (or master) is subsequently created by combining traditional craftsmanship and state-of-the-art technology which is then replicated in polyeurethane. 

01

The original forms for concrete patterns and some individual patterns are created by hand. They are molded out of plaster or cast of existing patterns. The models for the photo-concrete and single individual pattern are done digitally. An individual design or an image are transferred into a file for the CNC-mill by a computer. It cuts the pattern into board material (Exception: artico).

02

The positive 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 in-situ concrete.

06

After the concrete has hardened, the element can be easily removed. The formliner is ready to use again, up to 100 times depending on the type.