materials + Methods

MATERIALS, FINISHES + FABRICATION TECHNIQUES

materials

Material meets method

KEY CONSIDERATIONS

faq

methods

Case studies

material index

Colorful translucent epoxy resin samples showcasing layered pigment, texture, and light.

01 / Epoxy Resin

02 / Acrylic

Custom wood samples and finished wood pieces in varied tones, grains, and surface treatments.

03 / woods

Close-up of metal fabrication materials showing textured and finished metal surfaces.

04 / metals

Custom LED lighting installation creating illuminated architectural forms and color effects.

05 / LED lighting

Layered printed and vinyl graphics used in a custom environmental design installation.

06 / printed + vinyl graphics

Rigid substrate panels and dimensional mounting components used in custom fabrication.

07 / Rigid substrates + mounting systems

Live botanical elements and found objects incorporated into a custom experiential installation.

08 / botanical + found elements

ENVIRONMENT

The right material depends on
more than how it looks.

ENVIRONMENT

Where will it live? Interior or exterior, light exposure, moisture, temperature, traffic, and surrounding conditions all affect material choice.

FABRICATION

fabrication

How a material cuts, bends, prints, paints, bonds, fastens, or finishes affects what we can ask it to do.

DURABILITY

durability

How will it be touched, cleaned, maintained, or exposed to everyday wear?

SCALE + STRUCTURE

longevity + growth

How the work mounts, comes apart, gets updated, or needs to be accessed over time matters from the beginning.

LONGEVITY + GROWTH

finish + appearance

Color, transparency, texture, sheen, edge quality, and how the material changes under different lighting conditions.

installation + serviceability

How the work mounts, comes apart, gets updated, or needs to be accessed over time matters from the beginning.

INSTALLATION + SERVICEABILITY

scale + structure

Size, weight, thickness, span, and support can change what materials and construction methods make sense.

FINISH + APPEARANCE

budget

Material choice is only one part of cost. Fabrication, finishing, hardware, labor, and installation all play a role.

BUDGET

The right material depends on
more than how it looks.

ENVIRONMENT
Where will it live? Interior or exterior, light exposure, moisture, temperature, traffic, and surrounding conditions all affect material choice.

FABRICATION
How a material cuts, bends, prints, paints, bonds, fastens, or finishes affects what we can ask it to do.

DURABILITY
How will it be touched, cleaned, maintained, or exposed to everyday wear?

SCALE + STRUCTURE
Size, weight, thickness, span, and support can change what materials and construction methods make sense.

FINISH + APPEARANCE
Color, transparency, texture, sheen, edge quality, and how the material changes under different lighting conditions.

INSTALLATION + SERVICEABILITY

How the work mounts, comes apart, gets updated, or needs to be accessed over time matters from the beginning.

LONGEVITY + GROWTH
How the work mounts, comes apart, gets updated, or needs to be accessed over time matters from the beginning.

BUDGET
Material choice is only one part of cost. Fabrication, finishing, hardware, labor, and installation all play a role.

BETTER TOGETHER.

We rarely think about a material on its own. Some of the most interesting results come from how materials interact, contrast, and work together.

Layered wood, printed graphics, and integrated LED lighting used together in a custom experiential installation.

wood / LED LIghting / Print

Custom wood and metal detail featuring engraved geometric patterning and dimensional fabrication.

wood / metal

Metal, acrylic, and LED lighting combined to create an illuminated sculptural surface.

METAL / ACRYLIC / LED LIGHTING

CNC router cutting a dimensional pattern into wood during custom fabrication.

method index

01 / CNC Routing

Laser cutting and engraving a detailed pattern into sheet material.

02 / LASER CUTTING + ENGRAVING

Large-format printer producing a custom printed graphic on textured material.

03 / printing

Hands testing paint and stain samples for color and finish selection.

04 / paints + stains

Finished dimensional lettering and fabricated components prepared for final installation.

05 / finishing

Layered printed and dimensional graphic elements creating depth in an experiential display.

06 / layering

Resin being poured and mixed during a custom fabrication process.

07 / Pouring

Small fabricated components and layered materials being assembled into a custom display.

08 / Assembly

material meets method.

CNC CUT + PAINTED SUBSTRATE

Finished wood panel with laser-engraved artwork and integrated illuminated graphic elements.

LASER ENGRAVED + FINISHED WOOD

CNC CUT + LAYERED HDPE

Laser-engraved and hand-stained acrylic donor recognition panels with backfilled lettering.

Laser engraved + hand stained acrylic with backfilled lettering

Direct-to-substrate printed portrait and text on a finished wood panel.

DIRECT TO SUBSTRATE PRINT ON FINISHED WOOD

Layered scenic panels combining printed graphics, hand-painted elements, and integrated LED lighting.

LAYERED PANELS WITH PRINT + HAND PAINTED ELEMENTS WITH LED LIGHTING

CNC CUT + FINISHED METAL

Problem solving with materials

Custom Adventure Africa donor recognition installation at the Milwaukee County Zoo featuring an elephant centerpiece and integrated donor panels.

milwaukee county zoo
Adventure Africa Donor Recognition

Materials:
HDPE, Corten Steel, PVC

Methods:
CNC ROUTING + LAYERING + PAINT + HARDWARE + Locator backer

Problem:
Create an exterior installation that could withstand year-round conditions, require minimal maintenance, and support the design intent.

SOLUTION:
HDPE was selected for the durability the exterior environment required. Its properties then informed decisions throughout the project, from color and layering to lettering and assembly. Where HDPE couldn't give us exactly what we needed, we adapted the material, method, or construction.

Spolar Studio team assembling layered HDPE components for the Milwaukee County Zoo Adventure Africa donor recognition installation.

FABRICATION
The layered HDPE construction relied heavily on CNC machining and mechanical fastening to work with the material's properties.

Layered HDPE signage components showing the color palette and dimensional fabrication used in the Adventure Africa installation.

COLOR
Stock HDPE colors drove much of the palette; painted PVC was introduced where other colors were needed.

Close-up of engraved donor names with contrasting HDPE lettering inset into the Adventure Africa recognition display.

LETTERING
When conventional paint-filled engraving wasn't a reliable option, contrasting HDPE was inset into the engraved donor names.

Corten steel structural frame for the Adventure Africa donor recognition installation during fabrication.

Close-up of the intentionally weathered Corten steel finish used for the outdoor Adventure Africa donor recognition structure.

Rear view of the Adventure Africa donor recognition installation showing its Corten steel support structure and layered construction.

BUILT FOR THE ENVIRONMENT
Corten steel provided the strength needed for the exterior structure. We intentionally rusted the Corten to soften its appearance and create a weathered finish that felt appropriate to the Adventure Africa environment.

We look at more than appearance. Location, durability, scale, structure, finish, installation, maintenance, budget, and future updates all influence the material recommendation.
No. You can come to us with a fully developed specification or simply an idea of what you want the finished piece to feel like. We can help determine which materials and fabrication methods make the most sense.
Yes. Many of our projects combine materials such as wood, acrylic, metal, printed graphics, dimensional elements, and lighting. The key is making sure those materials work together visually, structurally, and during installation.
Yes. Material and fabrication decisions have a significant impact on cost. We can recommend alternatives that preserve the design intent while adjusting material, finish, construction, or installation approach to better fit the budget.
It depends on the material, thickness, edge quality, level of detail, and finished look. CNC routing works especially well for thicker materials and dimensional fabrication, while laser cutting is ideal for fine detail and precise cuts in compatible materials.
Absolutely. If a donor wall, recognition system, display, or branded environment will change over time, we can design the material and mounting system with future additions, replacements, or access in mind.
When appropriate, yes. Samples can help evaluate color, texture, transparency, finish, thickness, and how a material behaves under the lighting conditions of the space.
Ideally, materials are considered during the design process rather than after it. Material thickness, weight, fabrication method, mounting, lighting, and finish can all affect the design itself.