When asked by a landscape client to fabricate custom millwork cladding for a luxury skyscraper terrace in Manhattan, we knew it wouldn’t be a typical job. The design called for sleek, curved benches, planters, wall caps, and small walls—with all elements needing a high-end redwood look and lasting performance in an exposed rooftop environment. The material of choice? ACRE™ by Modern Mill, a durable, sustainable alternative to wood.
From the outset, we knew traditional methods like thermoforming wouldn’t cut it. Heat bending thermoplastic materials is unreliable for architectural elements, especially exterior applications, as it can create wrinkling and buckling (compression on the inside of curves, stretching on the outside). Heat-formed parts might revert toward their original shape when exposed to heat (e.g., direct sunlight), which could lead to failure.
Pushing the Limits
Instead of trying to force the material into submission, we decided to engineer a better way.
Our team took a bold approach: we removed material to allow flexibility and added a custom filler to hold the new shape. We used CNC machining to precisely cut curved shapes from sheet material, rather than heat-bending.
Using this method, we were able to achieve a ¾” radius—something even the material manufacturer didn’t think was possible. The result? Perfect, consistent curves with no risk of warping or distortion.
To support larger curves, we created custom ribs, allowing us to form a 3″ radius with stability and precision. These techniques opened up new design possibilities and pushed the boundaries of what ACRE could do.
The performance of the material exceeded everyone’s expectations. It was a great example of how our 20+ years of experience with synthetic materials and a willingness to experiment can lead to truly one-of-a-kind results.
Custom Finish in a Custom Color
Achieving the desired redwood finish was its own journey. The client had a very specific vision—something that looked exactly like natural redwood. We went through several rounds of samples, adjusting the tone each time, until the client sent us a physical redwood sample they wanted to match.
Working with our paint supplier, PPG Paints, we created a custom-mixed finish that matched perfectly. All new finishes have to be submitted to Modern Mill for testing and approval to maintain the ACRE product warranty. Once approved, it became the eighth officially recognized stain color for ACRE products.
All elements were fabricated and finished in our shop, then delivered ready for installation. That meant less time—and less mess—on-site, and perfect consistency across every component.
Built to Spec…and Beyond
At National Millwork, we don’t just build to spec—we build beyond it. Whether it’s pioneering new fabrication techniques or fine-tuning finishes down to the last detail, we’re always looking for the next opportunity to innovate.
Got a project with no clear playbook? We’re ready with custom millwork solutions. Reach out today.