Beyond Design created “Birch Bark” shingles and assembled the models for these canopies. Large (10’ X 14’) urethane rubber molds were spray applied on the models and foam composite mother molds were created to hold the shapes. A combination of spray foam and RIM was then sprayed on the inside surface of these canopies. The interior surface was created in a similar process from a mold made from a stripped log. These two surfaces were then laminated together with low density urethane foam and cut to size to fit the structural steel supports.