Production for the tiles took place in two identical silicone molds. The molds were held in a collapsible polypropylene boxes that allowed mounting bolts to be suspended into the casting at exact location for the unistrut rails. Given the surface complexity the use of the silicone allowed for the flexible molds to be removed in a manner that preserved the detail on the surface. A rigid mold would not have allowed for this to take place. Once the molds were filled with a hydro-stone mixture, the boxes were placed on a vibration table for 2 minutes. This ensured the surface texture and the removal of all air bubbles in the surface given the complexity of form.
During the production cycle we were able to cast up to 8 tiles a day. While the wall called for 60 tiles there was an extended period of one week where perfecting the mixture, the vibration duration, the set time were all experimented with in order to achieve an optimal production. To ensure accuracy sequencing of installation we mocked up mounting rails in our production area to test all the rails prior to shipping. It is here that we were able to tweak the spacing, the order of the rails, and establish best installation practices before having to do so in a very compressed timeframe at the final site.