Adapting electroforming techniques for the manufacture of architectural building elements

Abstract

A method of manufacturing an architectural building element, including providing a mold or master having a surface that is conductive. The mold or master is suspended in an electrolyte solution. Electro-deposition of a material disposed in the electrolyte solution upon the mold or master is performed using electrical current. The mold or master is removed from the electrolyte solution upon electro-deposition of a predetermined thickness of a coating of the material on the mold or master. The coating is then divorced from the mold or master to form an architectural building element.

What is claimed is: 
     
         1 . A method of manufacturing an architectural building element, the method comprising:
 providing a mold or master having a surface, the surface being conductive, the mold or master having a tessellated shape;   suspending the mold or master in an electrolyte solution;   electro-depositing a material disposed in the electrolyte solution upon the mold or master using electrical current;   removing the mold or master from the electrolyte solution upon electro-deposition of a predetermined thickness of a coating of the material on the mold or master; and   divorcing the coating from the mold or master to form a tessellated architectural building element.   
     
     
         2 . The method according to  claim 1  wherein the providing a mold or master comprises:
 forming a tessellated shaped blank from fiber board; 
 vacuum forming a synthetic around at least a portion of the blank; 
 separating the synthetic from the blank after the vacuum forming to form the mold or master; and 
 applying conductive material to the surface of the mold or master. 
 
     
     
         3 . The method according to  claim 1 , further comprising:
 electro-depositing a second material disposed in the electrolyte solution upon the mold or master using electrical current to achieve a varying material blend.   
     
     
         4 . The method according to  claim 1  wherein the providing a mold or master having a surface, the surface being conductive, comprises providing a mold or master having a conductive graphite surface. 
     
     
         5 . A method of manufacturing architectural building elements, the method comprising:
 providing a plurality of molds or masters each having a surface, the surface being conductive, each of the plurality of molds or masters having a tessellated shape that is complementary to the other of the plurality of molds or masters to be devoid of gaps therebetween when joined together;   suspending the plurality of molds or masters mold or master in an electrolyte solution;   electro-depositing a material disposed in the electrolyte solution upon the plurality of molds or masters using electrical current;   removing the plurality of molds or masters from the electrolyte solution upon electro-deposition of a predetermined thickness of a coating of the material on the plurality of molds or masters; and   divorcing the coating from the plurality of molds or masters to form a plurality of tessellated architectural building elements each being joinable with the others of the plurality of tessellated architectural building elements to be devoid of gaps therebetween.   
     
     
         6 . The method according to  claim 5  wherein the plurality of molds or masters comprises at least three molds or masters, each of the at least three molds or masters having a different tessellated shape that is complementary to the other of the at least three molds or masters to be devoid of gaps therebetween when joined together. 
     
     
         7 . The method according to  claim 5  wherein the plurality of molds or masters comprises at least six molds or masters, a first three of the at least six molds or masters forming a first set and a second three of the at least six mold or masters forming a second set, each of the first set having a different tessellated shape that is complementary to the others of the first set to be devoid of gaps therebetween when joined together, the first set collectively further defining a tessellated shape that is complementary to the second set collective to be devoid of gaps therebetween when joined. 
     
     
         8 . The method according to  claim 5  wherein the providing a plurality of molds or masters comprises:
 forming a plurality of tessellated shaped blanks from fiber board; 
 vacuum forming a synthetic around at least a portion of the blanks; 
 separating the synthetic from the blanks after the vacuum forming to form the plurality of molds or masters; and 
 applying conductive material to the surface of the plurality of molds or masters. 
 
     
     
         9 . The method according to  claim 5 , further comprising:
 electro-depositing a second material disposed in the electrolyte solution upon the plurality of molds or masters using electrical current to achieve a varying material blend.   
     
     
         10 . The method according to  claim 5  wherein the providing a plurality of molds or masters each having a surface, the surface being conductive, comprises providing a plurality of molds or masters each having a conductive graphite surface.