Scott System
Case Study
Precision Formliners for DARPA’s Reefense Coastal Defense Program
Project
Overview
Coastal erosion and flooding threaten communities across the United States, demanding innovative engineering solutions that combine durability with environmental sustainability. When Rutgers University developed a hybrid low-carbon concrete reef system for DARPA’s Reefense program, they needed a manufacturing partner capable of producing precision formliners for these critical coastal defense structures.
Scott System was tasked with creating reusable, high-durability urethane formliners that would enable the production of these innovative reef units.
The Challenges
The project required Scott System to fabricate reusable molds for hybrid low-carbon concrete reef units with complex geometry. The formliners needed to maintain precision while withstanding repeated use, a departure from traditional single-use mold applications.
The design demanded a solution that would allow for efficient demolding while preserving the structural integrity and dimensional accuracy required for Rutgers University’s specifications. Scott System needed to translate precise geometry data into physical molds that could deliver consistent, high-quality results across multiple casting cycles.
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The Vision
DARPA’s Reefense program uses engineered, low-carbon concrete reef units from Rutgers University as a hybrid, natural seawall solution to combat coastline erosion and flooding. Success hinges on producing these protective structures precisely, requiring durable, high-quality formliners for repeated use.
Proposed Solution
Scott System partnered with its sister company, Fort Miller Precast, to deliver a precision-engineered formliner solution. Using geometry provided by Rutgers University, the team designed a four-sided urethane rubber form with a cone-shaped core.
This configuration was specifically engineered to enable fast, efficient demolding while maintaining the precise specifications required for the reef units. The reusable design would allow for repeated high-quality casts without compromising dimensional accuracy or surface detail.
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Components for Success
Scott System selected High-Density Urethane (HDU) as the material for creating the master molds. This closed-cell foam provides the dimensional stability and machinability necessary for precision mold fabrication.
The company’s 5-Axis Thermwood Mill enabled the team to machine the molds with exacting precision, translating Rutgers University’s digital geometry into physical form. This advanced CNC equipment captured every detail of the reef unit design.
The cone-shaped core design proved essential to the solution’s functionality. This feature allows for efficient demolding, reducing the risk of damage to both the formliner and the cast concrete units while maintaining production efficiency.
Scott System cast the final formliners in urethane rubber, a material that balances the flexibility needed for clean demolding with the durability required for repeated casting cycles.
Products Used
5-Axis Thermwood Mill: Advanced CNC machining equipment for precision mold fabrication
High-Density Urethane (HDU): Closed-cell foam for master mold creation
Urethane Rubber Formliners: Four-sided reusable forms with cone-shaped cores
Custom Geometry Integration: Digital-to-physical translation of Rutgers University specifications
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The Outcome
Scott System provided high-durability urethane formliners for the DARPA Reefense program’s hybrid low-carbon concrete reef units. The reusable, four-sided forms with cone-shaped cores allow for quick, efficient demolding and repeated high-quality casts. The concrete reef units, engineered to combat coastal erosion and flooding, are now being tested by the U.S. Air Force as part of DARPA’s evaluation of innovative coastal defense solutions.
This project demonstrates Scott System’s capacity to deliver specialized manufacturing solutions for advanced research programs. By combining CNC machining expertise with material science knowledge, Scott System created formliners that meet the exacting standards required for government-funded coastal resilience initiatives.