A liner for a form is provided. The form allows for the creation of a precast concrete wall to be formed. The liner allows a building material, for example, brick veneer, to be placed in the liner in a pattern. The pattern may be a soldier course that can formed over openings in the precast concrete wall. When liquid concrete is poured into the mold and then hardens, the concrete holds the building material in place in the pattern produced by the liner.

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.

A mold for manufacturing interlocking, dry-cast concrete retaining wall blocks in an upright orientation comprises a mold box comprising two side walls joined to end walls to define a mold cavity, a top face, and a substantially open bottom face. Partitions configured to define a space between adjacent blocks or a space between a block and a side of the mold box extend parallel to the side walls of the mold box substantially from the top face into the mold cavity, to form first transverse portions of the profile of the top and bottom surfaces the blocks which do not include any undercut portion that would impede removal of the mold box in a substantially vertical direction. At least one removable insert comprises insert members which, when positioned in the mold box beneath the partitions, form remaining transverse portions of the profile of the top and bottom surfaces, the remaining transverse portions including at least one undercut portion. The insert members, when in position in the mold box for casting, are substantially in lateral alignment with respective bottom surfaces of at least some of the partitions and can be inserted and retracted through openings in an end wall of the mold box.

A block, block system and method of making a wall block. Multiple block embodiments with multiple embodiments of a visually exposed surface having three dimensional shaped areas and three dimensional angular valleys or joints that can be used to construct a patio, wall, fence or the like; the multiple embodiments creating a more random and natural appearance.

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.

Features for formliners to form a decorative pattern in a curable material and methods of using the same are disclosed. An improved formliner is disclosed with seamlessly connecting components that reduces the need for using adhesives for interconnecting a plurality of formliners in a pattern. Further, the formliner is configured to reduce and/or substantially eliminate visible seams in order to create a more natural appearance in a finished product of the curable material.

A formliner, sheet, system, and methods of use and manufacture are provided in order to provide a product that can minimize and/or eliminate visible seaming between interconnected formliners during fabrication of a pattern on a curable material. In some embodiments, the formliner can comprise raised sections that define interrelated inner and outer dimensions. Thus, a plurality of formliners can be interconnected by overlaying raised sections thereof. Further, the formliner can comprise one or more detents and one or more protrusions to enable engagement between interconnected formliners without requiring adhesives. In this manner, formliners can be interconnected in a nested manner such that visible seaming between the interconnected formliners is reduced and/or eliminated.

The appearance of natural rock faces are formed on planar panels or part portions disposed horizontally by stamping or texturizing a cementatious mixture of veneer material and then selectively applying colorant matter, which may include combinations of stains and mineral.

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.

Embodiments of a mold for making a retaining wall blocks are disclosed. The mold enables blocks to be made more quickly by enabling separation of each block from the mold housing when the block is cured sufficiently to enable separation. Once separated, the block can be permitted to fully cure away from the mold housing, while the mold housing is re-used to produce one or more other blocks. In one embodiment, among others, the mold has a movable bottom tray and a mold housing with at least one door. The mold housing has an opening designed to receive and introduce a fabrication material, such as concrete, into the cavity. Once a block is sufficiently cured, it is separated from the mold housing on the tray through the at least one door, and a new tray is inserted in the mold housing to make another block.