What Are the Production Challenges of Perforated GRC Decorative Panels? Precision Manufacturing and Qinglong Group's Technical Breakthrough

The production of openwork GRC decorative panels is a highly demanding technology that integrates "structural design, mold making, forming processes, demolding and curing" into one process. The core challenge lies in ensuring the strength, precision and yield of the openwork sections while achieving the desired aesthetic effect. Based on successful practices in projects such as the artistic openwork curtain wall of the Yirui Biotechnology Building in Shenzhen and the openwork railings of China Resources MixC One in Wuxiang, Nanning, Qinglong Group has summarized three major production challenges: high-fidelity mold fabrication and venting design for complex patterns, slurry flow and density control between narrow ribs, and deformation and breakage control of ultra-thin ribs during demolding and curing. For the "Dongguan Grass Weaving" facade of the Dongguan Women and Children's Activity Center, we innovatively applied a "combined soft-hard mold" technique together with vacuum-assisted forming, controlling the minimum rib width at 8mm, raising the openwork ratio to 45% and achieving a yield rate as high as 98%. Only by overcoming challenges can premium products be created.

The Ultimate Challenge of Mold Design and Fabrication

Openwork patterns mean the mold consists of numerous tiny protrusions and recesses, imposing stringent requirements on machining precision (up to ±0.1mm) and draft angle design. We use five-axis CNC precision machining for steel or resin molds, and design dedicated vent grooves at rib roots to prevent defects caused by air pockets. For extremely complex patterns, prototypes are made using 3D printing technology and then reproduced as production molds.

Precise Control of the Forming Process

The slurry tends to clog or fill incompletely when flowing through narrow openwork ribs. Qinglong Group uses a proprietary GRC slurry with high rheology and low shrinkage, and applies "pressure grouting" or "robotic directional spraying" processes to ensure every corner is fully filled. Meanwhile, vibration is applied to the back of the mold to assist venting and densification.

Meticulous Demolding and Curing Operations

The ribs of openwork panels are fragile, and uneven suction forces during demolding can easily tear them apart. We have developed a "step-by-step progressive demolding" process and an air-bag-assisted demolding system to release suction forces evenly. During the curing stage, custom brackets are used to keep components placed horizontally, preventing deformation caused by self-weight. Low-temperature steam curing with gradual heating and cooling is adopted to reduce stress.

Openwork GRC is the crown of GRC manufacturing technology. With deep process expertise and continuous technological innovation, Qinglong Group transforms the intricate patterns on design drawings into tangible architectural art.