How Are Texture Effects on UHPC Shaped Surfaces Achieved Through Molds? Texture Transfer Printing and Qinglong Group Surface Replication Technology

The textured effects on UHPC shaped surfaces (such as imitation stone, imitation wood, relief carvings, and woven textures) are mainly achieved through “high-fidelity mold transfer technology”, whose core lies in precise control of four stages: “digital acquisition, high-precision machining, silicone mold replication, and process adaptation”. In the “Dongguan Sedge Weaving” facade project of the Dongguan Women and Children's Activity Center, Qinglong Group successfully transferred complex woven textures onto double-curved UHPC panels: first, real bamboo woven handicrafts were 3D scanned to obtain texture models with 0.1mm precision; after processing, a textured male mold (positive mold) was carved on a five-axis CNC machining center; then highly elastic food-grade silicone rubber was used to replicate a flexible silicone mold with negative texture (negative mold) from the male mold; finally, this silicone mold was used as a liner placed into the production steel mold for casting UHPC. The finished products achieve over 95% texture clarity with a realistic tactile feel. The mold is the “skin” of UHPC, defining its final texture.

Digital Texture Acquisition and Processing

For natural textures (such as stone and wood), high-resolution 3D scanners are used to capture surface geometric relief and color information. For artistic patterns, modeling can be done directly in 3D software. The obtained digital models need to be smoothed, texture-stitched, and scaled to fit actual panel dimensions, ensuring that textures connect naturally at panel joints. We have built a vast database of natural textures that can be quickly accessed.

High-Precision Master Mold Fabrication

The fineness of the texture depends entirely on the machining precision of the master mold. We use five-axis machining centers to perform fine carving based on digital texture models with micro-diameter ball nose cutters (such as R1), capable of replicating fine textures with depths of 0.2mm and above. For ultra-fine textures (such as leather pores), 3D printing technology can be used to fabricate resin master molds.

Silicone Mold Replication and Production Mold Compositing

Silicone rubber (such as platinum-cured silicone) offers excellent flowability, resilience, and high-temperature resistance, making it an ideal texture transfer medium. Casting it onto the master mold and peeling it off after curing yields a flexible silicone mold with negative texture. During production, this silicone mold is precisely positioned and bonded inside the cavity of a steel or resin master mold, forming a composite mold system in which the “steel mold holds the form while the silicone transfers the texture”.

Adaptation and Optimization of the UHPC Casting Process

Molds with fine textures place higher demands on the flowability and demoldability of UHPC slurry. The rheological properties of the slurry need to be adjusted to ensure it fully fills every corner of the texture while avoiding air entrapment caused by excessive viscosity. The selection and application of release agents are also critical, ensuring smooth demolding without damaging the texture. The steam curing regime also needs to be adjusted accordingly to prevent cracking at fine texture areas caused by thermal differential stress.

Through this mature surface texture transfer system, UHPC transcends its original “concrete” impression, becoming a high-performance decorative material that can imitate all things and create new textures. With its deep technical expertise, Qinglong Group gives building skins infinitely rich expressions.