Advanced Manufacturing Capabilities
Custom Architectural Signage & Large-Format Fabrication — Engineering • Fabrication • Finishing • Nationwide Delivery
We Build What Others Can’t
Our Façade Product Line
Façade elements are the core of what we manufacture. Every technology described in this document exists to support one goal: producing a complete, dimensionally consistent exterior envelope system — not a single decorative piece, but the full set of components that make up a building’s face.
- Columns & Column Cladding — round, square, tapered, and spiral-fluted, with matching capitals and bases
- Pilasters — flat and engaged, sized to match full columns for consistent façade rhythm
- Cornices, Crown Moldings & Parapet Caps — continuous, full-length runs for roofline and top-of-wall detail
- Arcades, Colonnades & Archways — repeatable radius-matched segments for covered walkways and entries
- Balustrades, Railings & Balcony Systems — including Juliet balcony components
- Window & Door Surrounds, Keystones & Voussoirs — precision-matched openings across a full elevation
- Quoins & String Courses — corner and banding details for masonry-look façades
- Pediments, Gable Ornaments & Wall Medallions
- Faux Stone, Brick & Stucco Façade Panels — large-format textured wall panels
- Architectural Fences, Gates & Entry Monuments
Our Manufacturing Platform
Unlike traditional foam shops or stone suppliers, we combine multiple manufacturing technologies under one roof to produce virtually any architectural shape — from a single decorative corbel to a full-building façade system.
Engineering & Design
Our engineering team transforms concepts, sketches, and architectural drawings into production-ready solutions before a single piece of material is cut.
- CAD Engineering
- Shop Drawings & Production Drawings
- Value Engineering
- Material Selection
- Structural Design & Wind Load Considerations
- Installation Planning
- Custom Fabrication Design
- Toolpath simulation in SprutCAM and RoboDK before production — every custom column, arcade, or cornice profile is validated in simulation before it ever touches the machine
Large-Format Robotic CNC Manufacturing
Our production centerpiece is a fully synchronized 8-axis robotic CNC system, purpose-built for oversized precision components such as columns, arcade segments, and long architectural moldings:
- 6-axis industrial robot on an 8-meter servo linear rail, plus a servo-driven rotary table — robot, rail, and table interpolate as one coordinated kinematic system, not sequential passes
- 9 kW spindle, 18,000–24,000 RPM, 12-position automatic tool changer with automatic tool-length measurement
- 0.05 mm repeatability across a working envelope up to 2,700 mm — critical for matching capital proportions to column height and keeping arcade radii consistent across a full production run
- Expandable to a horizontal rotary positioner with interchangeable tube fixturing for columns, faux beams, mantels, and other long architectural components — no machine reconfiguration required
EPS Foam Fabrication
We specialize in large-scale EPS manufacturing for lightweight yet durable architectural elements, using a multi-axis hot-wire cutting fleet built specifically for oversized work:
- Multi-axis contour hot-wire cutters (2, 4, and 5-axis configurations), cutting widths up to 12 ft and lengths up to 16 ft — ideal for full-length cornices, fence panels, and arcade segments
- Hot-wire down cutters and slab slicers for raw block preparation at volume
- PolyMax 5500 densification system (250 lbs/hour) and high-capacity grinders for material reclamation and surface hardening — producing the 2–3 lb/ft³ density foam core used across our entire architectural product line
Applications: Architectural Columns • Cornices & Crown Moldings • Pediments • Balustrades • Arcade Segments • Window & Door Surrounds • Architectural Fences • Wall Niches • Decorative Trims
PU High-Pressure Foam Molding
Applications: Architectural Cornices & Crown Moldings • Trim Profiles • Corner & Panel Elements • Decorative Molding Detail
Advanced Polyurea Hard Coating
Our industrial polyurea systems — including a Graco H-XP2 Reactor and a dedicated 24 ft spray-foam/polyurea trailer rig — create the seamless, impact-resistant shell behind the 20-year warranty we stand behind on every column, cornice, arcade, and balustrade we produce.
- High Impact Resistance
- Weather & Moisture Resistant, including salt-air and coastal exposure
- Long Service Life, Exterior Grade — engineered to perform for decades
- Lightweight Construction
This is the difference between an architectural element that looks good on installation day and one that still looks flawless after twenty years of sun, rain, and coastal humidity.
Large Format 3D Printing
Capabilities: Master Patterns • Capital & Finial Prototypes • Custom Fixtures • Engineering Models • Sculptural Components
High Resolution Resin Printing
Applications: Capital Ornamentation • Keystone & Applique Detail • Design Samples & Miniatures • Precision Parts • Prototype Validation
Laser Cutting & Engraving
Capabilities: Acrylic • PVC • Wood • MDF • Composite Panels • Cutting Templates • Decorative Panel Detail
Rotational Casting
Applications: Finials & Ornamental Post Caps • Urns & Flower Pots • Decorative Objects • Custom Plastic Components
Fabrication & Assembly
Complete in-house production, including MIG welding for internal steel armatures and structural cores used in load-bearing columns and balustrade systems, mounting substructures, and hardware integration.
- Structural Assembly (steel-core columns and load-bearing balustrade systems)
- Welding
- Mechanical Assembly
- Hardware Integration
- Panel Bonding & Sectional Pre-Assembly
- Packaging
Surface Finishing
Polyurea • Texture Coatings • Stucco Systems • Faux Stone • Faux Wood • Faux Metal • Faux Aged Copper • Premium Paint Systems
Custom Paint Department
Nationwide Logistics
Custom Crating • Freight Coordination • LTL • Full Truckload • Jobsite Delivery • Free Interim Storage Until Site Readiness
Who We Work With
Our façade product line is built around four core client groups — each relying on us for a different stage of a building’s life, from blueprint to decades of upkeep.
Construction Companies & General Contractors
Façade packages engineered and produced to drawing tolerances, delivered pre-assembled and on schedule to keep new-build and renovation projects on the critical path.
Architects
A manufacturing partner that can turn a design intent — proportions, profiles, custom detailing — into a buildable, code-compliant façade system, with shop drawings and structural input at the design stage.
Designers
Custom color matching, faux finishes, and one-off ornamental detail for projects where the façade needs to match a specific aesthetic vision rather than a catalog profile.
Owners & Operators of Large Real Estate Portfolios
Property owners, HOAs, and facilities teams responsible for maintaining and restoring façades across multifamily communities, hotels, and commercial portfolios — supported by our 20-year warranty and repeatable production for matching replacement elements years after the original installation.
We also serve retail chains, hospitality groups, developers, and institutional facilities including healthcare, education, and government campuses.
Materials We Work With
Why GreenWall
One Manufacturing Partner. Every Technology. Unlimited Design Freedom.
Instead of coordinating multiple vendors — a foam shop, a mold house, a coating applicator, and a freight broker — our clients work with one experienced manufacturing team capable of handling engineering, fabrication, finishing, logistics, and production from concept to completion.
Owners & Operators of Large Real Estate Portfolios
- Engineering-Driven Manufacturing
- Large-Format Production
- Custom Fabrication Specialists
- 25+ Years of Architectural Expertise
- Advanced Digital Manufacturing
- Rapid Prototyping
- Nationwide Shipping
- Scalable Production for Multi-Building & Community-Wide Rollouts
- 20-Year Warranty on Every Element
- Made in USA
& specification catalog
Get the definitive guide to our custom decorative architectural foam shapes. This free catalog is packed with hundreds of design profiles, detailed technical specifications, and real-world project applications.
Have a project in mind?
Our dedicated specialists are ready to collaborate with you, turning your concept into a detailed plan with a transparent budget. Let’s bring your vision to life!