Patent ID: 8065028

Claim:
A method of constructing a display from composite materials, the composite materials being a plastic foam and a strengthening coating, comprising the following steps, creating a 3-D non-virtual model of the display to scale and smaller than the display, scanning the 3-D non-virtual model using a scanner, feeding information from the scanning into a program in a computer, creating a computer model of the display having surfaces in the program from the scanning information, creating a meshed model by surface meshing the computer model in a meshing program, solid meshing the computer model in a solid meshing program to create a meshed core of the computer model, adding a coating mesh to the surfaces of the meshed core, running a Finite Element Analysis or FEA on the meshed model in a FEA program, the FEA providing results from the analysis, selecting composite materials and dimensions of the composite materials to meet required building standards for a geographic location of the display from results of the FEA, creating the display from the composite materials and the dimensions found from the FEA by using a robotic forming system to form a surface of the display in plastic foam, coating the surface of the display with a strengthening coating, cutting the display surface from blocks of plastic foam and bonding the blocks of plastic foam together.