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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!

 

Ravensburger Play Figures

The game manufacturer Ravensburger is known worldwide for its board games and puzzles. In order to arouse the curiosity of customers, it strives to set up some popular game figures in front of the shops.

For this purpose, ACCENTFORM recreated a number of the game figures in sizes between 1.2-1.5 metres. These were four characters from four different games: the rabbit from Lotti Karotti, the penguin from Plitsch-Platsch Pinguin, the cockroach from Kakerlakak and the mole from Mole Company.

First, 3D models were created from the 2D figures. Then the greatly enlarged play figures were CNC-milled into a hard foam and encased in GRP using the hand-laminate process. Finally, priming and airbrush painting took place. Particularly important was the adherence to the corporate design. A base plate gave the objects a pedestal that protects against falling over and theft.

 

Ostrich sculptures

ACCENTFORM was commissioned by the German Armed Forces to produce two large ostrich sculptures after winning a tender.

The birds, which are a good two and a half meters in size, were initially carved by hand from templates. To give the sculpture stability, the feet were welded from solid steel tubing and attached to a steel pedestal. In order to obtain a hard and weatherproof surface, the bird sculptures were completely covered with a 2 mm thick layer of GRP using the hand-laminating process.

After the surface was filled, sanded and primed, the pair of ostriches could be given a realistic appearance by airbrush painting. Since May 2018, the giant ostriches have adorned the traffic circle near the Hardenberg barracks, greeting passing visitors to the garrison town of Strausberg.

Press reports:
Strausbergs Super-Strauße (MOZ)
Debate um gelbe Streifen (MOZ)

Bilder aus der Fertigung:

Horse figure Spirit

The wild mustang Spirit is the hero in a well-known Super RTL series and is now known not only to girls between 6-9 years. He is a special friend and soulmate of 12-year-old Lucky and accompanies her daily on her exciting adventures.

On behalf of the advertising agency PIE Five Marketing, ACCENTFORM produced a true-tooriginal 2m high Spirit figure made of GRP for the children’s TV station Super RTL. First, the body was milled from Styrofoam on a CNC machining center using the CAD files supplied. In order to obtain a hard and weatherproof surface, the soft Styrofoam surface was coated with a 2 mm thick GRP layer using the hand lay-up process. In order to create a smooth and even surface, the entire area must be filled, sanded and primed. This work process is very time-consuming and essentially affects the product quality. Professional painting by graffiti artist BeNeR1 breathed life into the horse sculpture. To protect the airbrush painting and for a nature-identical look, an extremely matte clear coat was finally applied. The finished sculpture is mounted on a mobile base plate with four wheels to ensure mobility at changing exhibition locations.

Process:

Paw Patrol Figuren aus GFK - Werbefiguren

Paw Patrol – dog figures

The popular Canadian series PAW Patrol inspires children of preschool age all over the world. The heroic rescue squadron, consisting of six rescuers on four paws, is the center of attention. We were allowed to produce two of these adorable characters in large format on behalf of the Advertising agency PIE Five Marketing the fearless, smart Skye and the athletic Chase.

First, the figures were milled from Styrofoam on a CNC machining center using the CAD files supplied. In order to obtain a hard and weatherproof surface, the soft Styrofoam models were coated with a 2 mm thick GRP layer using the hand laminate process. To create a smooth and even surface, the entire laminate layer had to be
sanded and primed.

The graffiti artist BeNeR1 ensured that the animal sculptures were painted true to the original. To protect the surface, matte clear lacquer was finally applied.

In the end, the beautiful sight of these two friendly dog heroes will delight not only children’s hearts…

Pictures from the production:

Styrofoam artwork – Katharina Grosse

The internationally renowned artist Katharina Grosse has temporarily transformed the Hamburger Bahnhof – Museum für Gegenwart – Berlin as well as parts of the outdoor area into an unmanageably large, colorful work of art. The boundaries between painting and sculpture are unconventionally dissolved in Katharina Grosse’s space-transcending and color-intensive artworks. Thus, in this exhibition entitled “It Wasn’t Us,” huge, rock-like elements, the floor inside and outside the museum, and parts of the façade also merge into a gigantic, three-dimensional painting in vibrant colors.

ACCENTFORM was commissioned to manufacture and assemble the oversized sculptural elements and was thus allowed to contribute to this extraordinary installation. This project presented us with a number of challenges, which we mastered in good cooperation with the client.

A Styrofoam model of the artwork, handmade by the artist in a scale of 1:50, was scanned externally and converted into 3D data. These served us as a template for 3D milling. A total of five Styrofoam objects were involved. First, a test model on a scale of 1:10 was milled using our 5- axis milling machine based on the 3D data. This model then served the artist in her studio as a
visual object for color matching and further adjustments, which were then milled by us on a scale of 1:5.

The 1:5 model was also revised again by the artist and after its approval we were able to mill the five rock-like objects in their original size. Due to the gigantic dimensions of up to 21 m in length and 7 m in height, these first had to be sensibly segmented. The milling time of 1,400 hours and the Styrofoam consumption of 1,050 m³ alone give an indication of the magnitude of this gigantic project.

After the parts were provisionally assembled, Katharina Grosse and her assistants worked on the surface with hot wire on site in our halls according to their ideas.

Skulptur vor dem Bemalen, Foto: Philip Radowitz

Sculpture before painting, photo: Philip Radowitz

Art exhibition “It Wasn´t Us”

The finished segments were delivered individually to Berlin and assembled on site in the historic hall of the Hamburg train station. The assembly by our team took nine days. The artist then made further adjustments to the surface and painted over the white “icebergs” with bright colors using a spray technique and integrated them into her space-blasting installation.

We were personally able to get an impression of this extraordinary work of art at the exhibition opening and are proud to have contributed to it within the scope of our possibilities.

As this work by Katharina Grosse is also a time-limited installation, the styrofoam elements will be 100% recycled after the end of the exhibition.

Bilder aus der Fertigung:

Bilder aus der Kunstausstellung:

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Stonehenge replica

The Stonehenge stone circle is the most famous Stone Age monument in Europe and is a UNESCO World Heritage Site. For a special exhibition of the LWL Museum of Archaeology in Herne, a full-scale Stonehenge replica as naturalistic as possible was to be produced as a monument that can be walked on and touched. We participated in the tender for this gigantic project and finally received the order. A total of 21 Stonehenge replicas on a scale of 1:1 were ordered, ranging in height from 4 to 7 m and up to 5 m wide.

Gigantic tasks

This literally gigantic order also presented us with some technical, time and logistical challenges. The 3D data of the giant stones provided by the customer first had to be divided into feasible sections. The individual elements were CNC milled from Styrofoam. Then, the large elements were merged together to form the stone replicas on a 1:1 scale.

The next step was to achieve the most realistic-looking surface possible for the stone giants. First, the “soft” Styrofoam was coated with a layer of polyurea hotcoat. This plastic coating significantly increased the compressive strength of the surface. The basis for the further coloration was then formed by freshly processed sarsen or bluestone optics. On the basis of photographic material and small original samples from Stonehenge, various types of sand were matched to each other and a suitable mixing ratio was determined. Because the replica stones should also
haptically resemble sandstone, the special sand mixture was sprayed onto the stone surface in combination with a dispersion adhesive. The details of the stone surface, as well as the color nuances, were finally worked out by airbrush painting.

Due to the large dimensions, the stones had to be precisely divided again for transport and assembly. The last hurdle was the assembly of the stones on site at the LWL Museum of Archaeology Herne. This was done by our team over two days. The huge stone models had to be assembled like a puzzle with the help of several scissor lifts and fixed to a substructure. The seams at the connection points were reworked by us after the assembly.

The impressive special exhibition about Stonehenge in the LWL Museum of Archaeology in Herne was opened on 23.09.21 and can be seen until 25.09.22.

Bilder aus der Produktion:

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Styrofoam sports car

By order of the company Neulant van Exel we were allowed to produce a fancy sports car model in original size.

Based on the supplied 3D data, a 1 : 1 replica was milled with high precision from a large-sized polystyrene block. The 4.8 m long model was produced on a 5-axis portal milling machine (10 x 4.5 m) in one clamping.
The car tires were milled separately and later movably attached to the model. The open-pored Styrofoam surface was closed with a mineral putty by manual processing and painted black/red. Further adjustments, as well as the mounting of the lamps were done by the customer.

The luxury sleigh was first used as a stage backdrop for the performance of a well-known German rapper duo.

Production pictures:

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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.

Giant meat cheese roll

YOU WOULD LOVE TO BITE INTO IT

We were commissioned by Globus Homburg-Einöd to create a giant meatloaf roll. This collos is now part of the walk-in exhibition in the popular shooting location – the Fancy Pop Up Gallery in Saarbrücken. Visitors are allowed to flash off there with this unique piece. Even the popular Saarland superhero Captain Maggi found the XXL “Fleischkäse Weck” to be a bite and has described it as “the dream of every Saarlander”.

The roll model consists of three parts. These were first individually milled from Styrofoam using the 3D data and then coated with a polyurea hotcoat. The surface was sanded and primed by hand. Afterwards, the graffiti artist BeNeR1 provided a “tasty” look.

As these shots attest, you can even make yourself comfortable on the robust surface of the giant huge bun.

Pictures of the production: