Custom Polyurethane Production Process for Architectural Decor

The custom production process begins with precise site measurements and structural layout planning. Accurately determining main axis dimensions is critical during this initial phase to prevent alignment errors during installation. Design drafts frequently incorporate historical details, such as Seljuk and Ottoman motif patterns, which require high geometric accuracy.

Due to the engineering required for accurate fitting, both field site discovery and 3D architectural modeling are provided as paid services. The fees for site inspection and initial 3D design are evaluated and quoted based on the specific scope and scale of the project.

Architectural polyurethane elements produced to order do not have standard fixed price lists. Because every custom item varies in dimensional scale, profile depth, and volume, cost calculations depend entirely on finalized geometry.

A formal cost quotation is generated only after the 3D design model is completed and approved. This approach ensures that material consumption, structural requirements, and tooling costs are accurately calculated prior to manufacturing.

Once the digital design is approved, production follows one of two technical paths based on production volume and geometric complexity:

• Direct CNC Machining: Used primarily for low-volume items, single prototypes, or oversized custom architectural features. The rigid polyurethane block is carved directly using multi-axis CNC routers.
• Casting Molds for Series Production: Used when identical profiles or decorative elements are needed in higher quantities. A master pattern is machined to produce durable molds, enabling efficient casting for serial output.

Polure selects the manufacturing path based on required unit volume and structural specifications.

Custom elements are produced from high-density rigid polyurethane featuring a closed-cell physical structure. The raw material density ranges between 150-220 kg/m³ (production target ~160 kg/m³) and 150-220 kg/m³ (production target ~160 kg/m³), with a standard production target of approximately 150-220 kg/m³ (production target ~160 kg/m³).

The physical material specifications include:

• Temperature Resistance: Maintains stability within -100 °C / +80 °C.
• Moisture Resistance: Water absorption stays below 1%, preventing internal rot or expansion.
• Surface Finish: Products are delivered with a factory primer. Applying an additional primer coat on site is optional depending on the topcoat system.
• Exterior Protection: For outdoor installations, applying UV-resistant paint is mandatory to prevent surface degradation.

Polyurethane structural profiles, including full columns, half columns, pilasters, and capitals, are strictly decorative elements. Polyurethane columns do not carry structural building loads under any circumstances.

When columns are installed around existing structural supports, the load-bearing weight must be fully sustained by steel or reinforced concrete cores. Polyurethane cladding is attached around the core solely for architectural appearance.

Proper installation of custom polyurethane profiles requires strict adherence to technical steps to maintain joint integrity:

• Surface Preparation: Substrates must be completely clean, dry, and level.
• Cutting: Profile ends must be cut at a 45-degree miter angle for corner joinery.
• Adhesion: Polyurethane (PU) assembly adhesive must be applied to all contact surfaces. Standard silicone adhesives are strictly forbidden due to insufficient load transfer.
• Mechanical Fixing: Fastening with mechanical screws is mandatory alongside adhesive application.
• Finishing: Joint lines are treated with joint filler, followed by sanding with 180-220 grit sandpaper. After surface preparation and optional extra priming, 2 coats of final paint must be applied.