Curved Wall Customer Requirements

• Curved wall approx 300’ long to enclose a children’s exhibit. Robust enough to survive children’s play

• Individual panels must be light enough to move and install by hand

• Curvature varies constantly along wall’s length.

Solution We created a curved sandwich panel with a foam core and resin impregnated plywood skins. Panels were fabricated on custom produced molds in 4’ x 8’ sections. Molds were recycled by re-cutting to accommodate the multiple changing curves with minimum cost and waste.

Customer : Design Craftsmen, Midland, MI

Installed 2006

Museum : Please Touch!, Philadelphia, PA - THEA award winner

Hanging Halo Customer Requirements

• A circular ring display 8’ diameter • Incorporate hanging points • Preferred to be very light for ease of

installation

Solution We created a ring from 3 curved sections. Wooden mounting points were incorporated into the top of the ring. Final ring weighed only 15 lbs allowing it to maneuvered into place and fastened by hand

Customer : D&P Inc, Lorton VA

Installed 2010

Museum : Arabian Horse Galleries, Lexington, KY – THEA award winner

Lightweight Ceiling Canopies Customer Requirements

• Large decorative canopies – up to 14’ x 4’

• Lightweight, easy to install

Solution We created a curved sandwich panel with laminate skins and a decorative face foil. Hardpoints are incorporated into the panels to mount pullthrough fastening system. Edges finished with extruded ABS trim.

Available from Fulcrum in custom sizes and finishes

Long Spiral Customer Requirements

• A double helix spiral, 2’6” diameter, 150’ long

• Must be lightweight to ease handling and installation

• Must be fabricated in sections

Solution After several prototypes we created a foam core spiral section that could be fabricated in 6’ lengths, and quickly joined at the jobsite using pre-fabricated plywood keys. Final piece will use decorative colored laminate skins and will weigh only 2lbs/linear foot.

Stage : Demo for customer

Large curved display walls Customer Requirements

• Curved walls 10’ high, 4” thick • Solid edges required

Solution We created large curved sandwich panels with multiple laminations to accommodate the wall thickness. Edges finished with inset plywood.

Customer : D&P Inc, Lorton, VA

Installed 2010

Museum : Arabian Horse Galleries, Lexington, KY

Curved Drywall Corners Customer Requirements

• Customer wanted curved corners for a room

• Must be installed and used like drywall • Inside radius 4”; Outside radius 8 1/2”,

bullnose to fit 2x4 studs

Solution We created a foam core sandwich panel with laminate backer skins. The outer face is pre-finished with drywall paper. Panels are produced in 8’ & 10’ sections. Panels are installed and finished exactly like standard drywall, including depth-set screws, standard taping, mudding, priming and painting. Edge tapers can be incorporated to match drywall.

Customer : Kayvala Inc, Midland, MI

Installed 2010Now available as a standard product – www.fulcrumcomposites.com/curve.html

Story Cubes

Customer Requirements

• Light enough for children or old people to easily pick up and flip around to read story across all faces

• Robust enough to withstand handling • Cost effective • Short lead time to produce 100s of

cubes

Solution We created a cube with a core of foam and thin plywood skins on two faces. The plywood supports the brittle laminate while adding very little weight. The fabrication method allows multiple cubes to be produced in a very short time.

Stage : Planning

Acoustic Diffusers Customer Requirements

• A means to diffuse and soften sound bouncing off sidewalls in a listening room/home theater

• Wall mounted • Adjustable in two axes to optimize (yes

some people really can tell the difference!)

Solution We developed a curved panel with diffuser slots, covered with speaker cloth. The combination of curved shape and slots diffuses diffuse reflections and absorbs across multiple frequencies. The panel is mounted on a two axis tilt & swivel bracket allowing the user to vary the panel orientation for optimum sound in their preferred listening spot.

Stage : Installed in home

Square Tube Customer Requirements

• A robust, modular tube for an indoor play area

Solution We developed a tube consisting of four curved panels, joined together with hidden tongue & groove joints

Stage : Prototyping

Modular Airfoil Display Customer Requirements

• A large airfoil section for a display with no visible joints on the curved faces

Solution We developed a process to inject PU foam into a cavity, bonding the decorative skin in place to create a very light yet strong monocoque component.

Stage : Was not implemented �. But it is still a great fabrication technique – ready to go and waiting for your application!

Curved Lightweight Stone Customer Requirements

• There was no customer for this – we are always experimenting with new materials and techniques, as always, striving to make our offerings unique and cool

Solution Looks, like stone, feels like stone because it actually is stone. It’s just extremely thin stone. So thin we can laminate it on our curved sandwich panels. The result looks like solid granite or sandstone but weighs almost nothing.

Stage

Ceiling Panels Customer Requirements

• Lightweight modular panels to be assembled into ceiling element

• Incorporate multiple hardpoints for assembly, lighting fixture and internal controls

Solution Nothing quite so fancy or unique as the curved panels but just to show we can also produce custom flat panels. Hidden wooden were incorporated as the panels were fabricated.

Customer : Design Craftsmen Inc, Midland, MI

Installed 2009

Museum : National Infantry Museum and Soldier Center, Columbus, GA