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Crown Moldings

Stop value-engineering your best ideas. Royal Foam engineers exclusive crown moldings and exterior cornice moulding systems that deliver the monumental look of stone or plaster without the weight, complexity, and budget overruns that kill creativity. For architects and developers who refuse to settle, we provide the tools to build bold, defining architectural statements that last.

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About our architectural molding systems

Go beyond standard trim with a precision-engineered molding system designed to define your building’s architectural character.

Architectural crown moldings, built without compromise.

Engineered for precision, designed for impact. Our crown moldings are more than just decorative trim; they are high-performance architectural elements crafted to define and elevate your building’s character. Forget the limitations of off-the-shelf products from Crown Molding Home Depot or Lowe’s. We create custom profiles to your exact specifications.

Each piece is a fusion of art and engineering, fabricated from a high-density, lightweight EPS foam core. This allows for the creation of large crown molding profiles and intricate decorative crown molding that would be structurally impossible or financially prohibitive with traditional materials. It’s the key to achieving a high-end aesthetic with smarter, more efficient construction methods.

Get a system that is engineered for perfection and delivered ready for rapid installation.

The science behind a flawless, feather-light facade

Our architectural cornices are built on an advanced material composite, engineered for a century of performance. The process begins with a structural, high-density Expanded Polystyrene (EPS) foam core, which we precision-cut using CNC technology. This ensures every miter, curve, and detail of your custom crown molding is geometrically perfect, guaranteeing flawless crown molding angles and seamless connections.

The core is then encapsulated in our signature polyurea hard coat. This isn’t just a coating; it’s armor. The spray-applied elastomer creates a monolithic, waterproof, and impact-resistant shell, transforming the lightweight foam into a structure with incredible resilience.

Finally, we apply an integrated, architectural-grade finish, like our stucco cornice moulding, that provides the authentic texture of masonry and superior resistance to weathering and UV degradation. This is how we build lightweight elements that outperform and outlast their heavyweight predecessors.

Assortment of crown moldings

Foam crown molding vs. traditional materials:
The Royal Foam advantage

Ready to build smarter?

Stop wrestling with materials that fight you at every step. Choose a lightweight, durable, and infinitely customizable cornice system—built to last, made in the USA.

Let's talk about your project today.

Discuss my project

Extremely Heavy & Demanding

Requires heavy foundations, cranes, and large crews, leading to higher costs and project delays.

Slow & Labor-Intensive

Slow, labor-intensive installation is plagued by weather delays, on-site modifications, and long curing times.

Constant Upkeep & Failure Points

Prone to cracking (concrete), rot (wood), and moisture damage (MDF), requiring constant and costly long-term maintenance.

Severely Limited

Designs are severely limited by material weight and complexity. Custom work is prohibitively expensive and slow.

High Upfront & Hidden Costs

High upfront costs for materials and labor are compounded by expensive, ongoing maintenance and repairs.

Virtually Weightless

Up to 90% lighter, eliminating the need for cranes or costly structural reinforcement.

Install in Hours, Not Weeks

Prefabricated, lightweight sections install in a fraction of the time, accelerating project timelines and reducing labor costs.

Zero Maintenance. 80-100 Year Lifespan

A waterproof polyurea shell makes it impervious to rot, insects, and cracking. An 80-100 year lifespan with zero maintenance required.

Unlimited Creative Freedom

CNC fabrication provides total design freedom. Any profile, from modern to historic, is created with perfect precision.

Lower Total Cost of Ownership

Significant savings on labor, equipment, and transportation result in a lower total project cost and a smarter investment.

Сustom crown moldings

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How to order your custom architectural molding

From your initial CAD file to job site delivery—our process is transparent, fast, and engineered for your success.

It all begins with a deep dive into your project. We work as your technical partner to translate creative intent into a solid, actionable plan.

  • Analyze Your Inputs: We review your architectural plans, CAD files, sketches, and inspirational images to understand your design from every angle.
  • Define the Scope: In a collaborative consultation, we discuss the project’s aesthetic goals, site conditions, and technical requirements to ensure a perfect fit.
  • Establish a Technical Blueprint: We finalize all specifications, from dimensions to finish textures, creating a clear roadmap for fabrication that aligns perfectly with your vision.
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We bridge the gap between concept and cost, providing you with the clarity and confidence to move forward.

  • Receive a Detailed 3D Visualization: We create and send you a precise 3D model, allowing you to see exactly how your custom architectural elements will look before production begins.
  • Get a Transparent, Itemized Proposal: You receive a clear, comprehensive quote with no hidden fees. We believe in total transparency, so you know exactly what you’re investing in.
  • Maintain Complete Control for Final Approval: We don’t proceed until you are 100% satisfied. You have the final say on the design and budget before we move to the next stage.
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This is where your approved design becomes a physical reality, crafted with an obsessive focus on quality in our 45,000 sq. ft. workshop.

  • Execute with Robotic Accuracy: Our state-of-the-art CNC hot-wire machines carve your decorative architectural shapes with flawless precision, matching your approved 3D model to the millimeter.
  • Armor for a Century of Performance: Our skilled artisans apply our signature Polyurea hard coat, creating a seamless, impact-resistant, and weatherproof shell designed for decades of durability.
  • Verify Through Rigorous Quality Control: Every single piece undergoes a multi-point inspection to ensure it meets our exacting standards for form, finish, and structural integrity.
Write to WhatsApp

Our commitment extends all the way to your job site, ensuring a smooth and successful installation.

  • Protect with Secure, Custom Crating: We build custom shipping crates for your elements, ensuring they arrive on-site in pristine, ready-to-install condition.
  • Streamline Your Installation: Your pieces are delivered pre-assembled and lightweight, designed to slash on-site labor time and eliminate the need for heavy machinery.
  • Support Your Crew to the Finish Line: We provide detailed installation guides and offer live Zoom support to answer your team’s questions, guaranteeing a perfect final fit.
Write to WhatsApp

It all begins with a deep dive into your project. We work as your technical partner to translate creative intent into a solid, actionable plan.

  • Analyze Your Inputs: We review your architectural plans, CAD files, sketches, and inspirational images to understand your design from every angle.
  • Define the Scope: In a collaborative consultation, we discuss the project’s aesthetic goals, site conditions, and technical requirements to ensure a perfect fit.
  • Establish a Technical Blueprint: We finalize all specifications, from dimensions to finish textures, creating a clear roadmap for fabrication that aligns perfectly with your vision.
Write to WhatsApp

We bridge the gap between concept and cost, providing you with the clarity and confidence to move forward.

  • Receive a Detailed 3D Visualization: We create and send you a precise 3D model, allowing you to see exactly how your custom architectural elements will look before production begins.
  • Get a Transparent, Itemized Proposal: You receive a clear, comprehensive quote with no hidden fees. We believe in total transparency, so you know exactly what you’re investing in.
  • Maintain Complete Control for Final Approval: We don’t proceed until you are 100% satisfied. You have the final say on the design and budget before we move to the next stage.
Write to WhatsApp

This is where your approved design becomes a physical reality, crafted with an obsessive focus on quality in our 45,000 sq. ft. workshop.

  • Execute with Robotic Accuracy: Our state-of-the-art CNC hot-wire machines carve your decorative architectural shapes with flawless precision, matching your approved 3D model to the millimeter.
  • Armor for a Century of Performance: Our skilled artisans apply our signature Polyurea hard coat, creating a seamless, impact-resistant, and weatherproof shell designed for decades of durability.
  • Verify Through Rigorous Quality Control: Every single piece undergoes a multi-point inspection to ensure it meets our exacting standards for form, finish, and structural integrity.
Write to WhatsApp

Our commitment extends all the way to your job site, ensuring a smooth and successful installation.

  • Protect with Secure, Custom Crating: We build custom shipping crates for your elements, ensuring they arrive on-site in pristine, ready-to-install condition.
  • Streamline Your Installation: Your pieces are delivered pre-assembled and lightweight, designed to slash on-site labor time and eliminate the need for heavy machinery.
  • Support Your Crew to the Finish Line: We provide detailed installation guides and offer live Zoom support to answer your team’s questions, guaranteeing a perfect final fit.
Write to WhatsApp

Our project gallery

Engineered solutions for every architectural statement

From modern commercial facades to historic restorations, our systems are engineered to solve the unique challenges of your project.

For Architects & Designers

Finally achieve the complex, multi-layered cornices from your renderings without fighting the constraints of weight and cost. We fabricate to your exact CAD files, providing the technical documentation you need to specify with confidence.

For Developers & General Contractors

Accelerate your project timelines and reduce labor costs. Our lightweight systems allow facade work to be completed faster by smaller crews, getting you to market quicker and improving your bottom line.

For Commercial Properties

Elevate your brand’s presence with a powerful architectural signature. Ideal for hotels, corporate headquarters, and high-end retail, our cornices deliver a premium look with zero long-term maintenance headaches.

For Historic Restoration

Perfectly replicate ornate, historic cornices with lightweight elements that won’t compromise the integrity of an older structure. We can match any historical profile with precision.

Before and after:
From forgettable to formidable

Before

The Challenge: A new commercial building had a clean but forgettable facade that lacked architectural presence. The developer’s initial plan for precast concrete cornices was value-engineered out due to extreme weight and exorbitant cost, leaving the building looking unfinished and generic.

After:

The Solution: We engineered and fabricated a complete exterior cornice moulding system from lightweight EPS foam. The custom, pre-finished sections were installed by a three-person crew in just two days using a simple lift, with no structural modifications required.

The ROI: The cornice transformed the building’s identity from a simple box into a sophisticated architectural landmark. This powerful new curb appeal directly increased the property’s valuation and attracted premium tenants faster than projected. It wasn’t a cost; it was an investment in architectural character.

Discover our work

A crown molding is more than trim—it's your architectural signature

Your exterior cornice moulding is more than an architectural detail—it’s the signature that communicates value before anyone steps inside. We engineer crown moldings that don’t just complete a building; they elevate its worth.

  • Establish Instant Prestige
    Our decorative crown molding adds undeniable sophistication to your facade, projecting an image of quality and permanence that attracts premium clients and tenants.
  • Engineer Out Long-Term Costs
    Forget the endless cycle of rot, cracking, and repainting. Our high-performance crown moldings are a one-time investment in lasting curb appeal, delivering a superior return through zero maintenance.
  • Define Your Architectural Brand
    Whether it’s a crisp, modern crown molding or a complex historical profile, we deliver custom crown molding that transforms your building into a unique and memorable landmark.
More about partnership

Voices of our clients

From your first idea to the final installation — our process is clear, fast, and designed to make every detail simple.

FAQ

See more

Your essential design & spec catalog

Get the definitive guide to our custom decorative architectural foam shapes. This free catalog is packed with hundreds of design profiles, detailed technical specifications, and real-world project applications.

Download Free Catalog

Let's build something great together

Have a project in mind?

Our dedicated specialists are ready to collaborate with you, turning your concept into a detailed plan with a transparent budget. Let’s bring your vision to life!

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Ready-made facade elements with factory assembly. Fast installation, fewer errors, and reduced costs.

Construction companies

Developers

Standardized solutions for neighborhoods. Quick delivery, unified style, no downtime.

Architects and designers

Сustom solutions for the project: 144+ textures, any shapes,
and technical documentation.

See more posts

Your essential design & spec catalog

Get the definitive guide to our custom decorative architectural foam shapes. This free catalog is packed with hundreds of design profiles, detailed technical specifications, and real-world project applications.

Download Free Catalog

Let's build something great together

Have a project in mind?

Our dedicated specialists are ready to collaborate with you, turning your concept into a detailed plan with a transparent budget. Let’s bring your vision to life!