Precise faux wood reproduction system and method

A method of manufacturing faux wooden components, the method comprising:

• identifying a desired authentic wooden component forming part of an original structure;
• scanning the desired authentic wooden component with a three-dimensional scanner without removing the component from the original structure, the three-dimensional scanner creating a 3D image file depicting a highly detailed representation of the authentic wooden component;
• exporting the 3D image file to a computer;
• using the computer to ensure that the representation is not twisted, bowed, or bent by making the represented wooden component more uniform and/or by removing imperfections therefrom, thereby forming a modified representation of the wooden component;
• placing a 3D printer in communication with the computer;
• using the 3D printer to print a form exhibiting the appearance and properties of the authentic wooden component in a desired size in accordance with the modified representation;
• constructing a mold based on an inversion of the form;
• pouring concrete into the mold;
• incorporating rebar and grid wire into the concrete within the mold;
• drying the concrete to form a cast of the faux wooden component comprising the rebar and grid wire;
• peeling the mold away from cast, revealing hardened concrete arranged as a representation of the faux wooden component;
• installing the faux wooden component;
• and
• coloring the faux wooden component.