Custom terracotta facade panels can be developed with project-specific profiles, face modules, colors, textures, joint details and special pieces. Customization is not unlimited, however. Extrusion geometry, drying and firing behavior, handling, span, fixings, test requirements, quantity and schedule must all be reviewed before a design is confirmed.

LOPO Terracotta works with project teams to translate an architectural intent into a manufacturable fired-clay product. The most successful developments begin before the elevation grid and corner details are frozen.

What can be customized?

Start with standard profiles where possible

LOPO’s existing profiles can shorten development time and reduce tooling risk. A standard section may still allow changes in length, surface or color within its production limits. Before commissioning a new extrusion die, compare the intended appearance with the current item listing.

A custom profile is most useful when it solves a real design requirement: a distinctive relief, a specific joint, deeper shadow, an unusual corner or a fixing condition that standard products cannot address. Creating a new section simply to make a small visual change may add cost and time without improving the facade.

Profile development is more than drawing a shape

An extrusion section must allow clay to flow evenly through the die and dry without unacceptable distortion. Internal webs, face thickness, ribs, grooves, hollows and edge geometry influence the result. The product also needs to be handled, fired, packed and installed reliably.

For this reason, the architect’s concept section is a starting point. The manufacturer may recommend adjustments to wall thickness, radii, relief depth or internal geometry. These changes should preserve the visible intent while improving manufacturability and dimensional control.

Color and texture require physical approval

Natural-fired color develops from the clay body and kiln conditions. Glazing adds further color and sheen possibilities. In both cases, a digital image cannot define the final production range accurately.

The approval process should move from reference images to physical samples, then to representative full-size panels. Review them under daylight and beside adjacent stone, metal, glass or mortar. For a large facade, a mockup should show the real joint width, orientation, corner and viewing distance.

Agree on an acceptable range rather than one isolated sample. Natural variation is part of fired clay, and later batches may not match the first firing exactly. Plan spare panels and retain the approved references.

A practical custom-development workflow

1. Design brief: provide project location, facade drawings, desired module, profile, surface, color and quantity.
2. Feasibility review: examine extrusion, firing, support concept, project loads, special pieces and schedule.
3. Profile refinement: coordinate the visible shape with internal geometry, tolerances and fixing engagement.
4. Tooling: confirm die or mould requirements, charges, minimum quantities and expected development time.
5. Prototype: produce trial units and inspect dimensions, surface, color and handling.
6. Mockup: install representative panels with real rails, clips, joints, corners and adjacent materials.
7. Technical approval: match available tests or define additional evidence required for the final product and system.
8. Production release: freeze references, quantities, cut pieces, packing marks, batches and spare stock.

Coordinate the fixing system at the same time

A custom face profile can affect the panel edge, clip engagement, rail position and allowable span. The facade consultant should review the load path from panel to clip, rail, bracket, anchor and supporting wall. Building corners and upper zones may require different support spacing because design wind pressures vary.

Custom panels remain the external cladding layer of a rainscreen. They do not replace insulation, the weather barrier or project fire-safety measures. Water management, cavity drainage, movement joints and interfaces must be detailed as part of the complete assembly.

Documents to request before approval

• Final profile and face-dimension drawing.
• Applicable tolerances and accepted appearance range.
• Panel weight for the approved size and profile.
• Product-specific technical reports relevant to the project.
• Fixing and subframe information for the proposed arrangement.
• Sample, mockup and production approval records.
• Packing, batch, spare-panel and delivery plan.

For guidance on matching reports to a product, read the terracotta facade panel technical data checklist. You can also review the LOPO terracotta panel range and manufacturing information.

To begin a custom development, send LOPO the profile drawing, elevation, finish reference, quantity, performance requirements and delivery destination.

Frequently asked questions

Does every custom panel require new tooling?

No. Changes in length, finish or color may be possible with an existing profile. A new cross-section or special shape is more likely to require a new die or mould.

Can LOPO match any color exactly?

A color direction can be developed, but fired clay and glaze have manufacturing ranges. Approval should use representative physical samples and an agreed tolerance rather than a screen value alone.

How early should custom panels be discussed?

Before the facade module, corners and fixing details are finalized. Early review leaves time for tooling, prototypes, mockups and any required testing.

Who completes the final facade engineering?

The project’s appointed facade professionals are responsible for final calculations, detailing and local compliance. LOPO supplies product information and supports manufacturing feasibility and samples.