concrete formwork · Structural matrices
Reliefs, logos and surfaces directly from the CAD file
A formliner is an insert used in formwork that gives concrete its surface structure: grooves, a timber effect, ornaments, lettering or a company logo. Mach-3D prints such inserts in rigid or elastic form – even as a one-off, without the need for a master pattern or casting tool.
As of September 2026
In short: Structural matrices are traditionally cast from polyurethane. This requires a master model and a casting mould, which only becomes economically viable above a certain surface area and quantity. The printed matrix skips both: the relief is created directly from the file. This is worthwhile for one-offs, logos, sample panels and small series.
Content
The formliner acts as the form face within the mould and carries the negative of the desired surface. What is recessed in the liner will later be raised in the concrete, and vice versa. This is how facade panels with relief, noise barrier walls with patterns, seating blocks with lettering or floor slabs with an anti-slip texture are created.
For recurring standard structures, manufacturers offer ready-made moulds made of elastic polyurethane that can withstand many castings. For anything individual, the traditional route begins with a master model from which the mould is cast.
| Situation | cast polyurethane mould | Printed die |
|---|---|---|
| Standard structure, large area, many castings | first choice | not cost-effective |
| Logo or lettering, just a few parts | Master model and casting mould required | straight from the vector file |
| sample tile for selection | Production value like a TV series | quick, change via CAD |
| site-specific art, one-off piece | Handcrafting on the master pattern | from scan or 3D model |
| Use in an existing steel mould | rarely available to fit precisely | tailored to the form |
A common misconception: We'll print that Master model or a sample plate, the die maker casts the production die from this. This means the motif is approved once before money is invested in the production tool.
Rigid inserts made of PP or ASA are suitable for structures without undercuts: grooves, chamfers, flat reliefs, recessed lettering. They require a draft angle on each flank.
Elastic gussets Those made from TPU or TPA can be removed from the cured concrete. This means that even small undercuts, sharp edges and deep textures are possible – features where a rigid insert would damage the concrete component. Both variants are resistant to the alkaline environment of fresh concrete.
Because FDM printing leaves a fine layer structure, we clarify in advance whether it will be lost in the design, is desired, or should be smoothed out. For smooth mirror surfaces around the relief, post-processing is necessary, see fair-faced concrete formwork.
To be honest: For hundreds of square metres of the same structure, the cast PU die from the manufacturer is cheaper and more durable. FDM cannot reproduce very fine details below the nozzle width. And the build volume of 900 × 900 × 1000 mm limits the piece; we assemble larger areas from segments, planning the joint into the motif.
Printed structural formliners make bespoke concrete surfaces affordable where a formliner tool is not financially viable: for the logo on the seating block, the sample panel for the architect, or the one-off piece for art in architecture. Rigid for simple reliefs, elastic for undercuts, always direct from your file and starting from a single piece.
Send us your logo, 3D model or a photo of the desired structure. We will check the relief depth, demouldability and the suitable material.