Case study · Industrial tooling
Large-format mold for concrete casting
Project · Industrial tooling
A concrete casting mold with a 4-meter cast surface.
An architectural precast producer commissioned a production mold for a curved concrete façade panel — 4 meters long with a continuous cast surface, used to produce 200+ units per year for a multi-year residential project.
200+
Units produced annually from the mold
Tooling build
- Master model 5-axis CNC in tooling board
- Production mold Fiberglass layup over master
- Rigidity frame Welded steel sub-frame
- Cast-cycle test 3 trial casts, finish verified
Large Gantry CNC
5-axis gantry with the capacity to machine the full 4-meter cast surface in one setup.
About this serviceDesigned for multi-year production.
The mold was built for durability — welded steel sub-frame, fiberglass production surface, and modular edge profiles for easy refurbishment. After three years of use, the surface is still within tolerance and the client has ordered a second mold for a parallel product line.
Process
Composite mold layup
Process
5-axis machining detail
"
Three years and 600 casts later, the mold is still within tolerance. We've ordered a second one for the parallel product line.— Operations Director, architectural precast producer
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