Micro-Engineered Poly-Fiber Geo-Composite Articles and Methods of Manufacturing the Same

A method of manufacturing a decorative article having a fiber-reinforced geo-composite wall with a thickness of between 4-10 millimeters (mm), comprising:

• (i) preparing a mold having a surface in a shape corresponding with at least one surface of the decorative article;
• (ii) calculating amounts of dry (Part A) components and wet (Part B) components needed to produce the decorative article within the mold;
• (iii) measuring out each of the respective Part A and Part B components;
• (iv) mixing the Part A components together in a cementious mixer until evenly dispersed therein;
• (v) mixing the Part B components in a separate container;
• (vi) gradually adding and mixing the Part B mixture into the Part A mixture to create a neat paste where the Part B to Part A mixture is combined at a ratio between approximately 0.38 and 0.50;
• (vii) painting a layer of the neat paste onto the surface of the mold, the layer of the neat paste having a thickness between 2 and 10 mm and forming two surfaces of the decorative product, the at least one surface engaged with and shaped by the surface of the mold and an opposite, exposed surface not engaged with the surface of the mold;
• (viii) finishing the exposed surface of the neat paste to define the thickness of the neat paste and to provide the exposed surface with a desired surface texture;
• (ix) allowing the neat paste to remain in the mold for a time period T1 to enable the decorative article to reach an initial curing point;
• (x) after the decorative article has reached the first curing point, removing the decorative article from the mold;
• and (xi) allowing the decorative article removed from the mold to dry for a time period T2 to reach a final curing point.