Method and system for fabrication of custom made molds and concrete architectural components

A method for preparing a three-dimensional form, from a work piece made of a polymeric material, comprising:

• supporting a work piece made of a polymeric material on a movable support table in communication with a computer processor, said support table capable of movement in response to commands from said computer processor;
• sequentially removing material from said work piece by use of an end effector comprising a hot-wire foam cutter, said end effector positioned at a distal end of a multi-task robotic arm in communication with said computer processor and moving in cooperation with said support table in response to commands from said computer processor, thereby forming a three-dimensional form having a desired shape;
• and,
• optionally milling said three-dimensional form subsequent to said step of sequentially removing material from said work piece.

A computer controlled system for constructing an architectural component from a three-dimensional form, comprising:

• a support table for supporting and moving a three-dimensional form, said support table being configured for translational and/or rotational movement;
• a multi-task robotic arm having a base and a distal end, said base being configured for controlled movement along a path proximate the support table, said distal end of said multi-task robotic arm being configured to extend, translate, and/or rotate relative to said base and further configured to include an end effector for applying successive layers of material onto and/or removing material from said form at said support table;
• optionally, a linear rail to which said base is attached;
• and,
• a computer processor containing instructions for controlling a sequence of movements of said support table and each of said base and said distal end of said multi-task robotic arm and for determining and sequentially applying layers of material onto and/or sequentially removing material from said three-dimensional form to form an architectural component of a predetermined shape and dimension.