Curved Douglas fir fins and thermoformed HI-MACS fascias for a high-end coastal self-build — developed by Cormorant Property and designed by Open Design Studio.
The architect's concept called for sweeping curved fins running across the elevation — a form that looks effortless on a drawing and is anything but in fabrication. Each fin follows its own geometry, and every component had to be dimensionally exact for the system to assemble correctly on site, in a coastal environment where materials and tolerances are tested hard.
Every element was modelled in Autodesk Inventor before a single cut was made. Working from the architect's design intent, we resolved the full fin substructure into buildable, machinable components, then manufactured each one on our 5-axis CNC at our Finchampstead workshop. The curved Douglas fir fins were machined to precise, repeatable geometry — no hand-fairing, no on-site guesswork.
The fascias were thermoformed and fabricated in HI-MACS solid surface. As an approved HI-MACS fabricator, DDB produced seamless curved elements that follow the fin geometry exactly and stand up to the marine environment.
A striking curved elevation delivered exactly as drawn — proof that complex architectural concepts become buildable when design and manufacture sit under one roof. From 3D model to machined component to finished element, everything was produced in-house in Berkshire.
Send us the drawings — we'll tell you how we'd make it buildable.