Fabricating Artificial Rock Panels (Molding and Spraying)

What happens here

The process begins by preparing various molds, often cast from real rocks, to capture intricate textures and shapes. A worker in protective gear then sprays the polyurethane liner directly into these molds. The liner adheres to the mold, forming a flexible yet strong skin. In some instances, stone dust is applied during or after the spraying to enhance the realistic appearance and texture. After the liner cures, the panels are carefully peeled from the molds. This step also shows large flat sheets being pulled from larger molds and being trimmed, demonstrating versatility in panel size and form.

Goal: Create custom-textured, lightweight rock panels.