A facing building member, a method of forming a facing building member and a method of forming a cladding panel. The facing building member is usable with other building members in forming a cladding panel. The building member has a front face and a rear side, the rear side being profiled by cutting with a water jet so as to provide at least one mechanical key on the facing building member.

This invention is an additively manufactured wall panel using computer aided design (CAD) and computer aided manufacturing (CAM) to design and manufacture multi-colored and multi-layered wall panels. This results in a variety of highly attractive, multi-colored wall panel faces ranging from brick, colored grout lines and multi-colored stones to multi-colored geometric designs. The design and manufacturing process greatly reduces the amount of precast cementitious materials by efficiently using higher quality materials. This reduces cost and weight while simultaneously producing a much more comprehensive, multi-functional wall panel complete with an interior frame, exterior insulation and an air, vapor and moisture barriers.

Disclosed is a method of producing a pattern for a decorative panel. The method includes applying a clear gel coat on a mold to form a clear layer. The clear layer is cured and then digitally printed with one or more inks so as to produce a pattern on the clear layer. Also disclosed is a decorative panel including a clear layer, an opaque layer and a pattern digitally printed on the clear layer, between the clear and opaque layers, such that the pattern is visible through the clear layer.

In accordance with an example embodiment, there is disclosed herein, a panel that comprises a plurality of ornamental sections having a predefined shape, the plurality of ornamental sections are arranged in rows that form a staggered arrangement with protruding rows and recessed rows between the protruding rows along at least one edge of the panel. A plurality of interior grooves are located between the ornamental sections, the interior grooves having a first width. A plurality of partial grooves having a second width are located along the at least one edge of the panel. Ornamental sections at an edge of a protruding row comprise convex curves having a first radius at their edges. Ornamental sections at the edge of recessed rows comprise concave curves having a second radius at their edges.

The invention is related to a method of manufacturing a wall panel and a wall panel system. The method includes: forming a glass-fiber reinforced rigid magnesium oxide layer including the steps of: pouring or injecting a slurry of uncured magnesium oxide into a mold, embedding glass fiber reinforcing material therein, and curing the magnesium oxide to obtain the glass-fiber reinforced rigid magnesium oxide layer having a first side and a second side; applying, to the second side of the rigid magnesium oxide layer, an insulation layer, the insulation layer comprising a foam; and applying to the first side of the rigid layer a veneer layer.

A facing building member, a method of forming a facing building member and a method of forming a cladding panel. The facing building member is usable with other building members in forming a cladding panel. The building member has a front face and a rear side, the rear side being profiled by cutting with a water jet so as to provide at least one mechanical key on the facing building member.

An article of manufacture is disclosed comprising a 3D-printed wall panel having an interior side and an exterior side. The exterior side comprises a textured surface formed by 3D printing the wall panel onto a textured form. In certain embodiments, the textured surface mimics at least one of natural stone, brick, and wood siding, and the medium printed onto the textured form is concrete. The interior side has 3D printed structural elements printed thereon designed to mimic conventional wood-stud framing in at least one of dimensions and spacing. A method for fabricating the 3D printed wall panel as described above is also disclosed.

An insulated modular brick system is provided that has the aesthetic qualities of a traditional brick system, that is cost effective, that has insulating characteristics, and that requires less labor to install than traditional brick systems and the aforementioned thin brick or brick veneer alternatives. The system comprises one or more insulated modular brick panels designed to be installed on a substrate of a building structure. The panel comprises an insulating foam core having a preselected thickness, an encapsulating material encapsulating the insulating foam core on at least first, second and third sides of the insulating foam core, and a plurality of thin bricks partially embedded in at least a front face of the encapsulating material at preselected locations.

The present disclosure relates to a system of providing a façade wall for a building. In particular, the disclosure presents a series of frames and frameworks which are adapted to integrate with a number of different designs of masonry slips. These masonry slips are parts of bricks, or other building items and the like, which by means of appropriately placed slots can integrate and be held by lips and extensions on the frames. Corner units, soffit panelling and free standing archways are also possible by appropriate combination of the concepts described herein.

A precast concrete panel and method for forming the panel are disclosed. A method of forming the panel to be used as a floor, wall, or roof structure includes positioning one or more forming members within a casting bed having a plurality of upright surfaces defining a generally rectangular interior area, the one or more forming members comprising an insulating material extending along a length dimension of the one or more forming members to define a plurality of rectangular-shaped channels in a parallel and spaced-apart relationship, placing uncured concrete within the casting bed and allowing the concrete to cover the one or more forming members and substantially fill the channels, and allowing the concrete to cure.