Advanced Manufacturing Capabilities
Custom Architectural Signage & Large-Format Fabrication — Engineering • Fabrication • Finishing • Nationwide Delivery
We Build What Others Can’t
Decorative Architectural Products is a full-service manufacturing company specializing in custom interior architectural elements — faux wood beams and truss systems, coffered and carved ceilings, ceiling dome systems, architectural column kits with capitals and bases, carved corbels, door surrounds, fireplace surrounds and mantels, and Juliet balcony kits — with the appearance of natural wood while weighing up to 50 times less.
From engineering and prototyping to nationwide production and delivery, we provide everything under one roof — a Florida-based manufacturing platform combining robotic CNC hot-wire machining, large-format EPS fabrication, high-pressure PU foam molding, industrial polyurea hard-coat protection, digital fabrication, and in-house logistics.
Whether you need a single fireplace mantel for a private residence or a complete coffered-ceiling and column package across a multi-unit development, our platform is built to deliver exceptional realism, precision, and scalability — backed by a 20-year warranty and Class A Fire Rating (ASTM E84) on our interior systems.
Our Façade Product Line
Interior architectural elements are the core of what we manufacture. Every technology described in this document exists to support one goal: producing individually engineered pieces with the authentic look and feel of hand-worked natural wood or carved stone — without the weight, cost, or maintenance burden of the real material.
- Custom Faux Wood Beams & Truss Systems — full ceiling truss assemblies engineered to any span
- Coffered Ceilings & Ceiling Dome Systems — precisely proportioned grid and dome layouts
- Carved Foam Ceilings & Faux Wood Ceiling Planks — for spaces where beam depth isn’t practical
- Architectural Column Kits, Capitals & Bases — 6″ to 36″ diameters, classical and custom profiles
- Carved Corbels — hand-textured, matched to beam and mantel finishes
- Front Door Surround Kits
- Fireplace Surround Kits & Faux Wood Mantels
- Juliet Balcony Decorative Kits
- Faux Stone Column Wraps
- Stucco Architectural Fencing Systems and Stucco Mailbox & Lamp Post Kits — exterior companion pieces for the same properties
- Acoustic Ceiling & Acoustic Panel Systems and Suspended Ceiling Systems
- Green Wall / Vertical Garden Panel Systems
Every beam, corbel, and ceiling panel is offered in four signature finish collections — Hand Hewn (axe-textured, rustic), Rough Sawn (visible saw marks, loft-style), Sandblasted / Driftwood (weathered, coastal), and Modern / Smooth (clean-lined, contemporary) — with every crack, grain line, and knot hand-textured by our artisans rather than pulled from a repeating mold. Textures and colors are fully customizable to each project.
Our Manufacturing Platform
Unlike big-box decorative foam suppliers, we combine multiple manufacturing technologies under one roof — inside a 45,000 sq. ft. Jacksonville, Florida workshop — to produce virtually any interior architectural element, individually engineered rather than mass-molded.
Engineering & Design
Our engineering team transforms a sketch, a CAD file, or a simple photo with circles drawn on it into a production-ready solution before a single piece of material is cut.
- CAD Engineering & downloadable CAD/Revit connection details
- Shop Drawings & Production Drawings
- Value Engineering
- Material Selection
- Structural Design & Wind Load Considerations (for exterior fencing and mailbox/lamp post kits)
- Installation Planning
- Custom Fabrication Design
- Detailed 3D visualization delivered before production — you see exactly how the beam, ceiling, or column will look, matched to the model to the millimeter
- Toolpath simulation in SprutCAM and RoboDK before production — every custom profile is validated in simulation before it ever touches the machine
Large-Format Robotic CNC Hot-Wire
Our production centerpiece is a fully synchronized 8-axis robotic CNC hot-wire system, purpose-built for the long, dimensionally exact components interior architecture depends on — beams, coffer grids, column shafts, and cornice runs:
- 6-axis industrial robot on an 8-meter servo linear rail, plus a servo-driven rotary table — robot, rail, and table interpolate as one coordinated kinematic system, not sequential passes
- 9 kW spindle, 18,000–24,000 RPM, 12-position automatic tool changer with automatic tool-length measurement
- 0.05 mm repeatability across a working envelope up to 2,700 mm — the reason a capital profile or coffer detail replicates identically across 200 units instead of “kinda close”
- Expandable to a horizontal rotary positioner with interchangeable tube fixturing for beams, column shafts, mantels, and other long components — no machine reconfiguration required
Supported by a dedicated 5-axis CNC foam router and computer-controlled specialty cutters for spiral-fluted columns, capitals, corbels, and ceiling dome segments.
Capabilities include: Faux Wood Beams & Trusses • Coffered Ceiling Grids • Column Shafts, Capitals & Bases • Carved Corbels & Brackets • Cornice & Trim Profiles • Fireplace Mantels • Ceiling Dome Segments • Door & Window Surrounds
EPS Foam Fabrication
We specialize in large-scale, high-density EPS manufacturing — the same lightweight core behind every faux wood beam, ceiling coffer, and column shaft we produce — using a multi-axis hot-wire cutting fleet built specifically for oversized work:
- Multi-axis contour hot-wire cutters (2, 4, and 5-axis configurations), cutting widths up to 12 ft and lengths up to 16 ft — enough for a full-span truss or a full-length beam in a single piece
- Hot-wire down cutters and slab slicers for raw block preparation at volume
- PolyMax 5500 densification system (250 lbs/hour) and high-capacity grinders for material reclamation and surface hardening — producing the dense foam core that gives every beam and column its solid, hardwood-like feel
Applications: Faux Wood Beams & Trusses • Ceiling Coffers • Column Shafts • Carved Corbels • Mantels • Door Surrounds • Fence Panels • Ceiling Dome Segments
PU High-Pressure Foam Molding
A dedicated high-pressure polyurethane (PU) foam molding line — including a high-pressure PU foaming machine, a mold-frame moving system, precision metal molds, automated panel and corner molds with pneumatic open/close cylinders, mold temperature control (440V), and a JYYJ-3H spray foam unit with heated hose and dual feed pumps — produces rigid, dimensionally precise PU profiles independent of our EPS/hot-wire process.
This gives us a second, purpose-built material path for capitals, bases, corbel and bracket profiles, and cornice detail that call for dense, rigid PU rather than carved EPS — molded rather than carved, and identically repeatable unit after unit across a full multi-unit development.
Applications: Column Capitals & Bases • Corbel & Bracket Profiles • Cornice & Trim Detail • Ceiling Dome Segments
Advanced Polyurea Hard Coating
Our industrial polyurea systems — including a Graco H-XP2 Reactor and a dedicated 24 ft spray-foam/polyurea trailer rig — encapsulate the EPS core in a thin, extremely durable, fully hydrophobic shell. This single layer is what lets the same beam, corbel, or column kit be specified indoors or on an exterior fence or mailbox post without changing the product.
- Class A Fire Rating (ASTM E84) — approved for interior use in restaurants, hotel lobbies, and other commercial public spaces
- Zero risk of rot, decay, or termite damage
- Hydrophobic and resistant to temperature swings, salt air, and wind loads for exterior-rated pieces
- Solid, dense feel comparable to hardwood by touch
This is the difference between a beam that looks like foam and one your client’s guests knock on, convinced it’s solid wood.
Large Format 3D Printing
An in-house fleet of 4 large-format filament (FDM) 3D printers, each with a 48″ × 48″ build volume, supports rapid production of full-scale prototypes, master patterns for capitals and corbels, and custom fixtures ahead of full-scale fabrication.
Capabilities: Master Patterns • Capital & Corbel Prototypes • Custom Fixtures • Engineering Models • Ceiling Medallion Components
High Resolution Resin Printing
4 photopolymer (resin) 3D printers, each with an 18″ × 18″ build volume, deliver the fine detail behind capital ornamentation, ceiling medallion motifs, and the individual knot and grain masters used to hand-texture every beam.
Applications: Capital Ornamentation • Ceiling Medallion Detail • Wood-Grain & Knot Masters • Design Samples • Prototype Validation
Laser Cutting & Engraving
A 185-watt laser system with a 48″ × 120″ working area handles precision cutting and engraving for mounting-cleat templates, acoustic panel patterns, and fine ornamental detail work.
Capabilities: Acrylic • PVC • Wood • MDF • Composite Panels • Cutting Templates • Acoustic Panel Patterns
Rotational Casting
2 rotational casting machines, each with a 48″ × 48″ working envelope and 200 kg part capacity, produce lightweight, hollow, high-strength components — supported by dedicated vibro-casting tables (4′ × 14′, 4,000 lb capacity) and a vacuum forming machine for shell and mold work.
Applications: Lamp Post & Mailbox Post Caps • Finials • Ceiling Medallions • Decorative Objects • Custom Plastic Components
Fabrication & Assembly
Complete in-house production, including MIG welding for internal steel armatures and structural cores used in load-bearing columns and balustrade systems, mounting substructures, and hardware integration.
- Mechanical Fastening System (Mounting Rails & Cleats)
- Structural Assembly for Truss and Ceiling Dome Systems
- Welding (for interior armatures where required)
- Mechanical Assembly & Hardware Integration
- Panel Bonding & Sectional Pre-Assembly
- Custom Packaging — each piece individually crated to prevent transit damage
Surface Finishing
Our finishing department is where a piece stops being “decorative foam” and becomes indistinguishable from natural material. Multi-layer, hand-applied texturing accounts for viewing distance and lighting, so grain, cracks, and knots read as authentic up close and from across a room.
Hand Hewn • Rough Sawn • Sandblasted (Driftwood) • Modern (Smooth) • Faux Stone • Faux Concrete • Stucco Finishes • Premium Paint Systems
Custom Paint Department
Color & Wood-Species Matching to Existing Interior Finishes • Corporate & Brand Colors • Metallic Finishes • Faux Finishes (Stone, Concrete, Aged Wood) • Clear Coats • UV-Resistant Coatings for Exterior-Rated Pieces
Nationwide Logistics
We manufacture in Jacksonville, Florida, and ship throughout the United States — with an in-house fleet of equipment trailers (up to 21,000 lb GVW) and forklifts up to 15,500 lb capacity, meaning pre-assembled, fully painted architectural elements move from our facility to the jobsite without depending on third-party freight for time-sensitive projects.
Custom Crating • Freight Coordination • LTL • Full Truckload • Jobsite Delivery • Free Interim Storage Until Site Readiness
Who We Work With
Our interior product line is built around the same core client groups as our façade and exterior work — each relying on us at a different stage, from first sketch to decades of use.
Construction Companies & General Contractors
Pre-assembled, lightweight interior packages that install in hours rather than days, with mechanical fastening and no wet chemistry on site — custom orders that ship complete rather than disappearing into a vendor black hole.
Architects
Unlimited freedom of form and geometry — custom radii, curves, and lengths often impossible in solid wood — plus downloadable CAD/Revit connection details and Class A Fire Rating documentation ready for regulatory approval.
Designers
Custom textures, wood-species matching, and hand-carved detailing that let a coffered ceiling or mantel become the focal point of a room, matched precisely to a designer’s concept rather than a catalog profile.
Owners & Operators of Large Real Estate Portfolios
Developers and property owners get budget predictability — reduced dead load means savings on structure and foundations — plus a 20-year warranty with no ongoing maintenance, refinishing, or mold-related issues, and identical appearance across every unit in a multi-property rollout.
We also serve interior designers, restoration specialists matching century-old ornament, hospitality groups, institutional facilities, and private homeowners.
Materials We Work With
Why Decorative Architectural Products
One Manufacturing Partner. Every Technology. Unlimited Design Freedom.
Instead of coordinating a foam shop, a mold house, a coating applicator, and a freight broker — our clients work with one experienced manufacturing team capable of handling engineering, fabrication, finishing, logistics, and production from concept to completion.
Our Core Advantages
- Individually Engineered — Not Mass-Molded
- Class A Fire Rating (ASTM E84)
- Up to 50x Lighter Than Natural Wood or Stone
- Zero Risk of Rot, Decay, or Termite Damage
- No Repeating Molds — Every Piece Hand-Textured
- 25+ Years of Architectural Expertise
- Advanced Digital Manufacturing
- Rapid Prototyping with 3D Visualization
- Nationwide Shipping
- 20-Year Warranty
- Made in USA
Have a question or suggestion? Write us or call us—we’re here!
Decorative architectural products manufacturer for interior and exterior applications.
25+ years of experience.
100% Made in the USA — factory in Jacksonville, Florida.