Abstract: Systems and methods for assembling multi-piece structural components, such as architectural columns, capitals, and bases, are disclosed. In one embodiment a column assembly is disclosed, comprising a first column portion and a second column portion. The first column portion includes a flange having a first keyed surface on which predetermined surface features are defined. The second column portion includes a second keyed surface that is configured to engage the first keyed surface. The second keyed surface includes a keying material having surface features that intermesh with the predetermined surface feature such that the first and second column portions are desirably aligned when mated. The surfaces features of the second keyed surface are defined in the keying material as a result of compressive engagement between the keying material and the predetermined surface features of the first keyed surface when the column portions are mated.

Abstract: A process for manufacturing a capital for an architectural column. The inside of a mold for an architectural column is lightly coated with a mold release. A first opening of the mold is placed upon a surface, and a plug is positioned on the surface within the first opening. Through another opening foam is poured around the plug. After the foam has hardened, the mold is removed from the surface. All other openings in the mold are securely covered. Then an elastomer is introduced into the mold, and the mold is rotated about multiple different axes. The introduction of the elastomer is repeated after the prior coating created by the introduced elastomer has become tacky but before the prior coating has become firm. After the final coating of elastomer has become tacky but not firm, foam is introduced into the mold.

Abstract: A capital to be placed upon a hollow column having a non-uniform cross section with a maximum inner dimension and a minimum inner dimension. The capital has an ornamental upper portion attached to a neck. The neck possesses a maximum outer cross-sectional dimension which is intermediate in size between the maximum inner cross-sectional dimension of the portion of the column intended to be occupied by the neck and the minimum inner cross-sectional dimension of the portion of the column intended to be occupied by said neck. The neck also has a minimum outer cross-sectional dimension smaller than the minimum inner cross-sectional dimension of the portion of the column intended to be occupied by said neck.

Abstract: A process for manufacturing a capital for an architectural column. The inside of a mold for an architectural column is lightly coated with a mold release. A first opening of the mold is placed upon a surface, and a plug is positioned on the surface within the first opening. Through another opening foam is poured around the plug. After the foam has hardened, the mold is removed from the surface. All other openings in the mold are securely covered. Then an elastomer is introduced into the mold, and the mold is rotated about three different axes. The introduction of the elastomer is repeated after the prior coating created by the introduced elastomer has become tacky but before the prior coating has become firm. After the final coating of elastomer has become tacky but not firm, foam is introduced into the mold.

Abstract: A machine for manufacturing a capital for an architectural column. The machine has a shaft with a releasable connector for attaching a mold for an architectural column to the shaft. Traditional means are employed to produce rotation of the shaft. Rotation of the shaft occurs in multiple axes, preferably two substantially orthogonal axes. These are preferably the pitch and roll axes. Rotation in more than two axes is, however, also contemplated. Also preferably, the shaft extends substantially symmetrically about the point of rotation for the first axis.

Abstract: A process for manufacturing a capital for an architectural column. The inside of a mold for an architectural column is lightly coated with a mold release. A first opening of the mold is placed upon a surface, and a plug is positioned on the surface within the first opening. Through another opening foam is poured around the plug. After the foam has hardened, the mold is removed from the surface. All other openings in the mold are securely covered. Then an elastomer is introduced into the mold, and the mold is rotated about multiple different axes. The introduction of the elastomer is repeated after the prior coating created by the introduced elastomer has become tacky but before the prior coating has become firm. After the final coating of elastomer has become tacky but not firm, foam is introduced into the mold.

Abstract: A process for manufacturing a capital for an architectural column. The inside of a mold for an architectural column is lightly coated with a mold release. A first opening of the mold is placed upon a surface, and a plug is positioned on the surface within the first opening. Through another opening foam is poured around the plug. After the foam has hardened, the mold is removed from the surface. All other openings in the mold are securely covered. Then an elastomer is introduced into the mold, and the mold is rotated about three different axes. The introduction of the elastomer is repeated after the prior coating created by the introduced elastomer has become tacky but before the prior coating has become firm. After the final coating of elastomer has become tacky but not firm, foam is introduced into the mold.