HyperWall™ Panel Production Process
A Streamlined Operation That Helps Reduce Lead Times and CostS
HyperWall panel production combines the benefits of advanced manufacturing processes and technologies with broad scope for customization and creative expression.
Foundational designs and models based on the requirements of each project, plus detailed shop and production drawings, guide all downstream activities. After kitting and molding, panels undergo essential post-mold treatments, including a high-performance Coraflon® ADS paint, to provide a durable and aesthetic surface finish.
The panels are then transported to the storage yard, where glazing is installed, eliminating the need to have that trade on-site.
Explore the process
Learn more about the innovative technologies and methods used to create HyperWall panels.
CNC Machine Tool
Our advanced Multiax CNC machining system combines subtractive and additive manufacturing processes in one platform, enabling unprecedented flexibility in tooling, mold making and fabrication. An OSAI open controller supports advanced machining functions, including helical interpolation, spiral machining, tool offset and length compensation, backlash correction and micron-level resolution.
Additive and Subtractive Integration
Molds and plugs are fabricated using bi-component pastes based on polyester, vinyl ester or epoxy resins, selected for performance requirements. A subtractive step first shapes a foam or similar substrate into a near-net form. The CNC then executes additive paste extrusion at automated speeds of 3–5 in./sec. After curing (typically within 24 hours), final machining produces accurate, finished geometries. This integrated workflow significantly reduces lead times and costs compared to traditional mold fabrication.
Vacuum-Assisted Resin Transfer Molding (VARTM)
VARTM is a widely used closed-mold process for fabricating advanced composite structures. Dimensional stability and high-quality surface finishes are achieved by using rigid tooling, while resin emissions remain contained within a sealed cavity. Substituting portions of the mold with a flexible membrane further enables uniform hydrostatic compaction, even for large or geometrically complex panels, thereby reducing bridging and improving fiber packing consistency.
Vacuum-assist serves a critical role in the production of HyperWall panels: by evacuating trapped air and moisture prior to infusion, the process reduces void content and enhances integrity. In this way, VARTM helps the HyperWall panel production team to achieve uniform preform compaction and controlled resin infiltration to satisfy structural design, weight and performance requirements.
Vacuum-assist serves a critical role in the production of HyperWall panels: by evacuating trapped air and moisture prior to infusion, the process reduces void content and enhances integrity. In this way, VARTM helps the HyperWall panel production team to achieve uniform preform compaction and controlled resin infiltration to satisfy structural design, weight and performance requirements.
Robotic Paint Cell
Designed in partnership with PPG and Yaskawa Motoman, a unique automated paint cell system integrates twin robotic applicators programmed for accuracy, efficiency and repeatability. Parts move through a dedicated paint booth on a conveyor, where robots apply both primer and color coats with consistency. The system incorporates rapid color-change capabilities, precision mixing near the applicator to reduce waste and advanced atomizer technology to ensure smooth, even films, even for mica-filled formulations.
By standardizing paths and maintaining consistent deposition, high-volume robotic automation allows scalable production to match industry growth, uniform film build and aesthetic accuracy.
By standardizing paths and maintaining consistent deposition, high-volume robotic automation allows scalable production to match industry growth, uniform film build and aesthetic accuracy.
Coraflon ADS Fluoropolymer Coating
Coraflon ADS is a two-component fluoropolymer coating engineered to resist chalking, weathering and ultraviolet degradation. Its chemically inert carbon-fluorine bonds provide exceptional stability when exposed to sunlight, maintaining color vibrancy and surface integrity for decades while outlasting conventional finishes.
Available in a wide palette of solid, metallic and mica finishes, Coraflon ADS also meets AAMA 2605 performance standards.
Available in a wide palette of solid, metallic and mica finishes, Coraflon ADS also meets AAMA 2605 performance standards.