digital mould design
Concrete formwork: 3D design and CNC machined solutions to efficiently and accurately form complex shapes in concrete.
Digital Mould Design (DMD) offer world leading concrete formwork, mould design and fabrication technologies. We specialise in the design and supply formwork for: commercial builders, large scale domestic developments, landscaping and urban development. Whatever concrete form you require we can make your mould — precast or insitu. DMD apply leading edge technologies to create formwork for any shape, finish and budget. These technologies include: laser cut steel, CNC machined and CNC hot-wire cut polystyrene foam (EPS) with or without coatings, fibreglass and 3D printing.
Melbourne Square Level 8 landscape by Delta Group moulds for curved concrete seating by DMD. Photo Sam Slicer 
Bolte Tower 11 Docklands, gas fire pit, cast insitu, wire cut EPS mould including vents 
Anembo Gold Coast, facade mould 
Precast balustrade 
Precast stair treads Monach University 
Atlantis Gold Coast precast seating 
Clyde School precast seating 
Fire place cast insitu 
GRC moulds in steel to produce segments for seat / planter 
Bolte Tower 11 Docklands Melbourne single leg table with lighting and LED strip underneath, machined EPS mould 
Capitol Grand curved concrete seats precast 
Two steel moulds at different radii produce accurate parts that are aligned to form elliptical shapes
Concrete moulds and formwork
Based on architectural drawings, CAD files, sketches or briefs from clients, DMD use 3D computer modelling to digitise the concrete form. From these 3D models we design and develop mould / formwork systems suitable for a range of fabrication methods including: CNC 5 axis machining, CNC routing, CNC hot-wire cutting, laser cutting, water jet cutting, CNC sheetmetal folding and 3D printing. All these CNC (Computer Numerical Control) processes are fast and extremely accurate, even for complex shapes with compound curves.
We also design and supply bracing systems and integrated mould assembly features that result in very fast installation and pours without problems. The mould sections are made in easy to handle sizes and lock or bolt together on site to create runs of any length. Minimal surveying is required as our systems connect in a way that ensures the shape and geometry are correct. For example Melbourne Square Level 8 required 200 lineal metres of landscape seating / retaining wall. Stage one moulds of over 100 lineal metres were set up in four days by a team of four (including steel reinforcing) and poured in one day. Every project has unique challenges but innovative solutions come easily to us.
Beyond moulds and bracing DMD offer design resolution all the way through to pour schedules, which are important in economical shared-mould situations. For example in moulding the terraces for Sea World Atlantis we consolidated the curves that snaked over one hundred metres. We reduced the original fifteen different arc and radius combinations down to five with only small deviation from the original design, then developed a plan so shared moulds would work in four pours to suit the timeline of the project. The new layout only slightly differed from the original design but a fraction of the cost. We took an extremely complex situation and made it simple to deploy on site, with minimal set-out — bolting our steel moulds together formed the varying arcs sweeping from convex to concave with perfect tangency.
curved seating and terracing, curved walls and slab edges, retaining walls, facades, bollards, playgrounds, furniture, planters, sculpture… on any scale
We can supply moulds with short lead times Australia wide. Our steel moulds are fast to produce — laser cut with assembly features (we call self-jigging), they are quickly and accurately fabricated with minimal welding. Steel is a great option for durable moulds that give a class-one finish. 3D printing, fibreglass, foam composite and CNC machined form-ply assemblies are also within our suite of solutions.
DMD are Australia’s leading digital mould and formwork designers with many years experience in concrete and GFRG moulding. We specialise in solving the complex forms found in contemporary Australian architectural projects. Our achievements in traditional formwork over the years lead us to more and more complex projects. We soon found CNC machining is the most efficient way to achieve this level of complexity and it is fast and accurate compared to hand-made formwork. Some of the current concrete designs we see are impossible to make formwork for by traditional methods.
Recent clients and designers: Delta Group, Multiplex, CBD Landscape Construction, LU Simons, Mirvac, Oculus, Living Landscapes, TCL, CUSP, Bates Smart, Jack Merlo, Metricon, Normark Landscapes, Tiama Constructions, BLR Provincial Construction, Elite Shop-fitting, Foxwood, Beejay Concrete Services, Clifton Formwork, Benzini Precast, Concrete Architecture, CYP Design & Construction, John Holland, Lendlease, Tim Davies Landscaping, Auscast, Pace Group, Concrete Republic, Concrete Precast Systems (CPS), Rork Projects, Cobild Constructions, BRD Industries, ULS Group, Intrec, Symal Contractors, P&H Civil Landscape, RMB Construct, Groupline Constructions, Slab Culture, Landscape Plus, Buxton Construction, Sydney Precast, Terrazzo Australian Marble, LB Concrete Solutions, Hayball, City Group Constructions, Treu Constructions, Melbourne Architectural Precast, Outside Ideas, Trikcon, Caledonia Constructions, Cappah Group, Arenco, Fender Katsalidis, SEE Civil
Projects: MONA Hobart, Hotel Hotel Canberra, Capitol Grand Melbourne, The IVY Sydney, Park Hyatt Sydney, Southern Ocean Lodge Kangaroo Island, Kinnears Building Melbourne, Melbourne Square Melbourne, Monash College Melbourne, Tower 11 Melbourne, Sapphire by the Gardens Melbourne, Queens Wharf Brisbane, University Of Melbourne New Student Precinct, Rodd&Gunn Melbourne, Jewel Tower Gold Coast, MCG Melbourne, Rodd&Gunn Brisbane, Melbourne Metro Tunnel, Sea World Atlantis QLD, Curtin University Perth, West Side Place Melbourne, Clyde School Melbourne, Grafton Waterfront Precinct, Australian Catholic University Melbourne, Living Carlton Melbourne, Mildura Riverfront Precinct Redevelopment, Long Island Festival Place Brisbane, Home Docklands, Thompson St South Melbourne, Percy Treyvaud Memorial Park Melbourne, West Side Place Melbourne, 380 St Kilda Rd Melbourne, Melbourne Airport, Anembo Gold Coast, Austin Mercy Hospital Melbourne, Melbourne Quarter, Windermere Estate Melbourne, Idée Fix Margaret River, Western Sydney Airport, The Carlile Melbourne, Harpley Town Centre Melbourne, Oasis Residences Melbourne, Nantilla Rd Melbourne, Burwood Ave, Lillidale waste to energy facility Melbourne, Gore St Melbourne, Port Dock Adelaide, Liverpool St Melbourne, Footscray Hospital Melbourne, Parker House QLD, Heirloom Armadale, Kew Recreation Centre, Baldivis Police Station WA, Flinders West Melbourne, Mira Gold Coast, Mooloolaba sea wall
Contact:
Sholto Turner
Ph: 0408 532 817
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