Surface coating – STYROFOAM®

PS stands for expanded polystyrene and is usually referred to as Styropor®. The material has a very light weight and can be easily shaped into the desired form by milling, sawing or hot wire. The surface of EPS/Styropor® is open and not resistant to moisture, so objects made of this material are not suitable for outdoor use without a coating. Styrofoam surface can be easily painted, coated or laminated, which increases its durability and stability and extends the range of applications. As a rule, styrofoam and hard foam models are intended for further surface coating by GRP/CFRP in hand laminate process or special painting. In the following table we present some possibilities of surface coating with their advantages and disadvantages.

	Styrofoam object without coating The desired object is milled by machine according to 3D data and the Styrofoam surface is kept uncoated. This variant is inexpensive, yet not well suited for outdoor use and repeated use.
	Coating Polyurethane The object is coated with a 2-component and solvent-free polyurethane coating. The coating is very UV light stable, high gloss, fast drying and available in RAL & NCS. This unique coating is color fast and is used in interior and exterior applications.
	Coating Epoxy The object is poured over with an epoxy resin. The material can be poured or painted or trowelled over various surfaces. After a few hours, the material hardens to a very hard and resilient plastic that can be easily sanded and painted. It is classified as flame retardant according to DIN 4102 B1 and is suitable for indoor and outdoor use without hesitation.
	Coating casting-laminating system The object is coated with a liquid 2-component casting and laminating system. It consists of a combination of liquid water-based acrylic resin and mineral powder. By varying the base materials used, materials with a wide variety of properties are created. Molded parts made of this material can be demolded and machined after only 40-90 minutes. It is weatherproof, UV-resistant and suitable for indoor and outdoor use. The material cures without shrinkage under low heat generation. Light, thin and very strong laminates can be produced by layering or laminating with glass fiber scrim.
	Coating Adhesive primer/filling paint/brush with texture The object is coated with a primer/adhesive primer based on acrylic copolymer. Filler paint is then applied with a brush. Filler Paint is a water-thinnable acrylic paint with a very high solids content and extremely high filling power. Suitable tools are used to give the surface a texture and then a metallic paint is applied.
	Coating Adhesive primer/filling paint/brush without texture The object is coated with a primer/adhesive primer based on acrylic copolymer. Then Filling Paint is applied smoothly with a brush. Filler Paint is a water-thinnable acrylic paint with a very high solids content and extremely high filling power. Finally, an appropriate metallic paint is painted.
	Coating Adhesive primer with gun The object is coated with a primer/adhesive primer based on acrylic copolymer. The primer is applied with a gun and then painted with a metallic paint.
	Coating with GRP (fibreglass plastic) The object is first painted with a solvent-free two-component coating compound based on polyurethane. Then covered with several layers of fiberglass soaked in the resin by hand (hand laminate method) in layers. After curing, the surface, sanded, filled and painted with as desired. This surface is particularly smooth, strong and weather resistant.
	COATING WITH POLYUREA The material polyurea impresses with its properties of flexibility, wear resistance, water and weather resistance, as well as very good chemical resistance. The two-component polyurea system usually reacts very quickly, which is why this material is always processed mechanically with 2-component mixing systems. read more

For other coating options not listed here, please feel free to contact us by phone at 05721-93708 – 0 or by E-mail: We will be happy to advise you individually according to your needs.

The final design of the surface is done according to your wishes and color specifications. You can choose from the entire range of RAL colors up to metallic effect paints.

However, the quality and cost of a paint job vary considerably. In order to apply the optimal coating and painting, the location and purpose of your object should be considered in advance.

We are looking forward to your inquiry!

: Figuren Teile aus Styropor

: Objekt – Öllampe aus Styropor

: Riesenei aus Styropor

Hot wire cutting

Preferably 3D objects and contour cuts such as letters and logos made of Styrofoam, Styrodur or EPP are cut via a CNC-controlled hot wire cutting machine. The cut is made by a hot wire that moves vertically. With special computer programs it is possible to produce any desired shape according to customer requirements.

: Mr & Mrs aus Styropor

: Schriftzug HEIMAT aus Styropor, 2m hoch

: Styropor Buchstaben

: Logo aus Styropor mit Heißdraht geschnitten

: X- (Logo Cinemaxx)

: XXL Hand, mit Heißdraht geschnitten, farbig beschichtet

: XXL-Diagramme aus Styropor

: XXL-Puzzel aus Styropor

: Styroporpuzzel – Detail

: Heißdrahtschneiden Q, laminiert und lackiert

: Riesen Q iür das Event st fertig

Asteroid VESTA

The asteroid Vesta about 516 km (almost 321 miles) in diameter is the second largest asteroid that has ever been discovered. It orbits the Sun in 3.63 years and at a speed of 69,624 km / h (19.34 km / s, over 43,000 MPH). A research probe had already digitized the asteroid and ACCENTform used this to create a replica at the 1:300,000 scale. The model weighs about 200 kg (440 lbs) and is about 1.70 m (5.6 ft) in diameter..

The surface of the asteroid Vesta consists of iron, magnesium and pyroxene rock. However, our model consists of an inner polystyrene core and a rigid outer shell coated with a modelling paste. It was pre-milled in a Styrofoam block by our five-axis machining center; then, it was coated and shaped again. To achieve an authentic surface, the model was painted and coated with sand.

Fibreglass Boulders

Project: Five-Star Hotel Kameha Grand

For the atrium of the new hotel building and for the traffic circle in Bonn, ACCENTform produced, supplied and coated 14 different sized fibreglass boulders of 1000 mm (3.3 ft), 1500 mm (5 ft) and 2500 mm (8.2 ft) in diameter. The fibreglass boulders have polystyrene – rigid foam core that, due to the fibreglass 5 mm (0.2 in) thick coating, is weather resistant.

The designer Marcel Wanders (moooi) from Amsterdam, developed the exclusive design of fibreglass boulders. They were carried out, according to for the Five-Star Hotel Kameha Grand typical flower design.

Huge Molecule Model

Molecule – Company Logo Replica

Production of an oversized molecule as an eye-catching exhibition booth display.

The molecule floated at the height of 5 meters (5.5 yds.) in the center of the booth. For the production of the spheres, three were made 840 mm (33 in) in diameter and one 1200mm (47 in) in diameter, as well as three connection pieces. These orbs were formed into a molecule by means of the connection pieces. After being primed and smoothed, the surface of the molecule model was prepared for a glossy and reflective coating.

Subsequently, the molecule model was painted blue and yellow to give it a spectacular touch.

GRP Shower Gel Bottle

The AXE Effect – With us, even in oversize

To increase the publicity of the various AXE Shower Gels to the intended younger target market, the Doyko agency set up eight 3.5-meter (11 ½ feet) high shower gel bottles as shower cubicles at the open-air festivals.

ACCENTform developed these large items ready for shower use. In planning, design, choice of materials, construction, labeling, installation and transport logistics, the Dokyo advertiser could fully rely on ACCENTform GmbH with its broad experience in custom fibreglass design.

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For a realistic construction, our technical product designers scanned an original bottle by means of an area laser and then developed not only the geometry of the half shells, but they also shaped the corresponding transportation racks. Thus, these original showers, along with the festival music, could be sent on tour to various locations in Germany.

As always, the adherence to delivery dates and strict budget compliance by ACCENTform were commended by the client. This allowed the Doyko agency to concentrate on other promotional activities. To the production connoisseur, you may have noticed that while everything appears to be from a single casting, the shells were produced by ACCENTform in much more efficient process – utilizing the hand lay-up method.

Azipod® Model

THIS IS HOW CRUISE SHIPS ARE POWERED TODAY

Few people know that large cargo and cruise ships today are powered by electric motors – with the electric motor hanging directly with the ship’s propeller on a rotating bearing in a nacelle underneath the ship. Today, the well-known “ship’s diesel” only generates
the electricity required for this purpose and can now run highly efficiently and therefore much more fuel-efficiently and environmentally friendly, regardless of the ship’s speed.

These innovative electric drive systems from ABB® are called Azipod® and not only lead to a lot of advantages for the environment and economy. Thanks to the compact design, space requirements are also significantly reduced: no rigid shaft, no control system also means more space for cabs and cargo, fewer wearing parts and less vibration..

This innovative propulsion system, which is part of the equipment of a new and “greener” cruise class, was to be impressively presented at the visitor center of MEYER WERFT in Papenburg. Therefore, ACCENTFORM received the order to build a 1:1 model of an Azipod® propulsion system – no problem for the ACCENTFORM team.

After the production molds for the nacelle and the five different blades had been prepared, the individual components were manufactured in hand laminate with a wall thickness of 5mm. A FRP hemisphere serves as the tip of the propeller. Attachments for the floor and ceiling are located on the individually removable wings. All segments were primed, the nacelle was also painted in our factory. The painting of the five blades was done by the client.

After completion of all remaining work, the propeller was assembled in Papenburg. The impressive model can now be admired in the MEYER WERFT visitor center.

Space Shuttle Rocket Engine

ACCENTform was commissioned by Creative Services KG to produce an exhibit where the visitors experience the effect of blasting off into space. This true 1:1 fibreglass replica of a space shuttle rocket engine is displayed at the German Aerospace Centre (DLR) in Bremen. The aim was to comply with the customer’s requirement that both the insides and the outsides have an authentic-looking surface that realistically captures the look of the space shuttle main engine assembly.

The engine nozzle, made by ACCENTform, was installed vertically, in the correct height of nearly 5 meters (5.5 yds.) and assembled on-site. This was a huge challenge for all persons involved. Thanks to the FRP material, the rocket engine had the following final specification: 2.23 meters (2.4 yds.) in diameter, 2.7 meters in height (3 yds.), was extremely light, weighing in at 100 kg (220 pounds) and also very stable. Because the access area of the exhibition hall was tight and hard to access, the engine nozzle has to be divided lengthwise into four single parts that were manufactured separately and then assembled on-site to form the finished rocket engine. Finally, the entire engine nozzle, with a total surface area of approximately 25 m² (27 yds².), was painted in matte black.

In order to provide visitors with a unique and tactile experience, the requisite fuel pumps were installed by the client and for added realism, an infrared heater was mounted inside the shuttle engine. To comply with existing safety regulations, ACCENTform made the fibreglass model in the fireproof design according to DIN 5510 (S4, SR2, ST2) standards. Because of the radiant heating, the visitors standing beneath the rocket engine felt an intense afterglow, while above them the imaginary space shuttle lifts off into space.

Display Model Tractor, GKN

Display Model of Tractor Mechanical Components

ACCENTform was commissioned by the GKN Company to make a tractor model at the 1:2 scale for the Agritechnica trade fair in Hanover. The model represented the company’s diverse products ranging from a drive system, to a tractor wheel, and included the driveshaft, at one of the world’s biggest agricultural fairs. The special feature of this project was the use of the unusually varied number of different manufacturing processes.

Using the manufacturing process “Rapid prototyping”, the original 3D data sets were scaled to the required size and divided so that they could be milled in polyamide with a 3D printer. Here, it produced more than 120 3D printing parts. These parts were subsequently glued together to be the drive shafts, clutches, multi-disc brakes, and the complete drive system. For the modules, the 3D printer made the fibreglass wheels, which were supported in the mold and model-making by our machining centre. The Plexiglas frame and chassis of the tractor model were designed by our design team, before being nested and passed on to an external company for laser cutting and bending.

The tubular frame, which represents the outline of the tractor, was first designed as a 3D CAD model and using the CNC pipe-bending machine, were bent and welded into shape. Finally, over 400 items were installed for this project.

Model of window-frame-sash

For the Fensterbau Frontale 2014 trade show, ACCENTFORM produced oversized, approx. 2m high models of a window-frame-sash combination by mid-March 3 2014. We milled the individual details (frames, seals, reinforcements) in Obomodulan 160. The individual parts were sealed, filled and prepared for painting. The customer chose different paint to represent the details. After successful painting, ACCENTFORM joined the details as in the original. The window profiles were placed on the bases provided on site.