Upon receipt of project drawings and scope details, our team of project estimators will prepare a detailed quote outlining quantities and any available options including value-engineering opportunities. A general manufacturing lead time estimate will be provided.

Samples are typically prepared for color and texture at the project specification stage or after the project is awarded and are signed off by the architect. Production will not begin until sample approval is obtained or waived.

Where existing samples are not available, most new patterns are manufactured by 5-axis CNC machines to ensure accurate dimensions, crisp details, and rapid production. Where ornate details or the appearance of aging is required, Formglas' experienced team of sculptors will produce the pattern. Most patterns are =machined on furniture grade MDF, or are produced using clay, plaster foam or metal. All completed patterns go through a quality control process to ensure dimensional accuracy.

Part production, depending on the type of material, is carried out by a multi-step hand or spray lay-up process. Raw materials used may be a gypsum, cement or polyester resin matrix. The matrix (depending on which raw material used) may contain pigments, aggregates and polymers for aesthetics and long-term durability; and part reinforcement is achieved with glass fiber, foam core, wood, steel or plastic (depending on the material and fastening details). Ultimately, a high-strength, lightweight and thin profile is created to meet the architect's specifications and to match approved shop drawings.

Depending on the type of material produced (GRG, FRP or GFRC), the part may go through a secondary process of finishing to achieve the desired surface texture or finish. Detailed quality control and touch ups may be performed to ensure the finest quality finished product.