The document describes several curved wall and display solutions created by Fulcrum Composites to meet clients' requirements for lightweight, durable, and easily installable curved structures. Key details include the use of sandwich panel construction with foam cores and laminate or plywood skins to create curved walls, canopies, rings, and other curved decorative elements for museums and exhibits. The panels are fabricated in sections and joined on-site, allowing complex curves to be achieved through a modular process.

1. Curved Wall
Customer Requirements Solution
• Curved wall approx 300’ long to enclose We created a curved sandwich panel with a
a children’s exhibit. foam core and resin impregnated plywood
Robust enough to survive children’s skins. Panels were fabricated on custom
play produced molds in 4’ x 8’ sections. Molds were
• Individual panels must be light enough recycled by re-cutting to accommodate the
to move and install by hand multiple changing curves with minimum cost
• Curvature varies constantly along wall’s and waste.
length.
Customer : Design Craftsmen, Midland, MI
Installed 2006
Museum : Please Touch!, Philadelphia, PA - THEA award winner

2. Hanging Halo
Customer Requirements Solution
• A circular ring display 8’ diameter We created a ring from 3 curved sections.
• Incorporate hanging points Wooden mounting points were incorporated
• Preferred to be very light for ease of into the top of the ring. Final ring weighed only
installation 15 lbs allowing it to maneuvered into place and
fastened by hand
Customer : D&P Inc, Lorton VA
Installed 2010
Museum : Arabian Horse Galleries, Lexington, KY – THEA award winner

3. Lightweight Ceiling Canopies
Customer Requirements Solution
• Large decorative canopies – up to 14’ x We created a curved sandwich panel with
4’ laminate skins and a decorative face foil.
• Lightweight, easy to install Hardpoints are incorporated into the panels to
mount pullthrough fastening system. Edges
finished with extruded ABS trim.
Available from Fulcrum in custom sizes and finishes

4. Long Spiral
Customer Requirements Solution
• A double helix spiral, 2’6” diameter, After several prototypes we created a foam
150’ long core spiral section that could be fabricated in 6’
• Must be lightweight to ease handling lengths, and quickly joined at the jobsite using
and installation pre-fabricated plywood keys. Final piece will
• Must be fabricated in sections use decorative colored laminate skins and will
weigh only 2lbs/linear foot.
Stage : Demo for customer

5. Large curved display walls
Customer Requirements Solution
• Curved walls 10’ high, 4” thick We created large curved sandwich panels with
• Solid edges required multiple laminations to accommodate the wall
thickness. Edges finished with inset plywood.
Customer : D&P Inc, Lorton, VA
Installed 2010
Museum : Arabian Horse Galleries, Lexington, KY

6. Curved Drywall Corners
Customer Requirements Solution
• Customer wanted curved corners for a We created a foam core sandwich panel with
room laminate backer skins. The outer face is pre-
• Must be installed and used like drywall finished with drywall paper. Panels are
• Inside radius 4”; Outside radius 8 1/2”, produced in 8’ & 10’ sections. Panels are
bullnose to fit 2x4 studs installed and finished exactly like standard
drywall, including depth-set screws, standard
taping, mudding, priming and painting. Edge
tapers can be incorporated to match drywall.
Customer : Kayvala Inc, Midland, MI
Installed 2010Now available as a standard product – www.fulcrumcomposites.com/curve.html

7. Story Cubes
Customer Requirements Solution
• Light enough for children or old people We created a cube with a core of foam and thin
to easily pick up and flip around to read plywood skins on two faces. The plywood
story across all faces supports the brittle laminate while adding very
• Robust enough to withstand handling little weight. The fabrication method allows
• Cost effective multiple cubes to be produced in a very short
• Short lead time to produce 100s of time.
cubes
Stage : Planning

8. Acoustic Diffusers
Customer Requirements Solution
• A means to diffuse and soften sound We developed a curved panel with diffuser
bouncing off sidewalls in a listening slots, covered with speaker cloth. The
room/home theater combination of curved shape and slots diffuses
• Wall mounted diffuse reflections and absorbs across multiple
• Adjustable in two axes to optimize (yes frequencies. The panel is mounted on a two
some people really can tell the axis tilt & swivel bracket allowing the user to
difference!) vary the panel orientation for optimum sound
in their preferred listening spot.
Stage : Installed in home

9. Square Tube
Customer Requirements Solution
• A robust, modular tube for an indoor We developed a tube consisting of four curved
play area panels, joined together with hidden tongue &
groove joints
Stage : Prototyping

10. Modular Airfoil Display
Customer Requirements Solution
• A large airfoil section for a display with We developed a process to inject PU foam into
no visible joints on the curved faces a cavity, bonding the decorative skin in place to
create a very light yet strong monocoque
component.
Stage : Was not implemented . But it is still a great fabrication technique – ready to go and waiting for
your application!

11. Curved Lightweight Stone
Customer Requirements Solution
• There was no customer for this – we are Looks, like stone, feels like stone because it
always experimenting with new actually is stone. It’s just extremely thin stone.
materials and techniques, as always, So thin we can laminate it on our curved
striving to make our offerings unique sandwich panels. The result looks like solid
and cool granite or sandstone but weighs almost
nothing.
Stage

12. Ceiling Panels
Customer Requirements Solution
• Lightweight modular panels to be Nothing quite so fancy or unique as the curved
assembled into ceiling element panels but just to show we can also produce
• Incorporate multiple hardpoints for custom flat panels. Hidden wooden were
assembly, lighting fixture and internal incorporated as the panels were fabricated.
controls
Customer : Design Craftsmen Inc, Midland, MI
Installed 2009
Museum : National Infantry Museum and Soldier Center, Columbus, GA