How a cast-needle tree is made
The trees we sell are cast in a Ukrainian workshop in Uman. Here is what that involves — and why a cast branch costs more than a film one.
Foresterra is a shop, not a manufacturer: the trees are made in Ukraine, in a workshop in Uman. Below is how the process works there and what a buyer should know about it.
The stages in brief
| Stage | What happens | What it means for you |
|---|---|---|
| Raw material | 100% virgin SABIC polyethylene (Netherlands) | even colour and a springy branch |
| Casting | each sprig is pressure-moulded in a mould taken from real spruce | full needles with a vein and a rounded tip |
| Assembly | the crown is assembled by hand, branch by branch, on a metal frame | the tree opens in about a minute |
| Packing | the folded tree goes into its box | the same box is where it lives between seasons |
Each stage shows in the finished tree: colour and springiness come from the raw material, needle texture from the mould, and how quickly the tree becomes a full crown from the assembly.
Raw material
The material is 100% virgin SABIC polyethylene (the Netherlands). Virgin means not recycled: recycled stock is cheaper but gives patchy colour and turns brittle over time. Colour and springiness of the branch are exactly what set a tree apart from a cheap one.
Polyethylene for casting usually arrives as pellets: they are melted and fed into the mould under pressure. That is why the quality of a finished branch starts before casting — with the choice of raw material.
Shape
The branch is pressure-moulded in a mould taken from real needles. That is why it has a vein, thickness and a rounded tip rather than the straight edge of cut film.
The mould decides what a given model’s needles are like: longer or shorter, denser or sparser. So cast trees of different models differ not only in height and crown width but in the texture of the branch itself.
Assembly
The crown is assembled by hand, branch by branch, on a metal frame. The finished tree opens in one minute — the folding design means the buyer has nothing to put together.
Once opened, the sprigs take 30–60 minutes to fluff and the crown reaches its full volume. The frame is built for decorations: each branch holds about 1 kg.
Cast needles and PVC film in one crown
Many models combine both materials: cast needles on the outside, where they are seen and touched, and PVC film inside the crown. The inner layer fills the space near the trunk so the crown looks dense, while the cast needles set the look.
Why cast needles don’t shed
A cast sprig is a single piece, not a bundle of cut film strips clamped in wire. Nothing in it can come loose, so after the season there are no needles on the floor or in the box.
How to recognise a cast branch by hand
- The needles are rounded, with a vein down the middle, not a flat strip
- The needle tip is rounded, not cut
- The sprig is springy: press it and it returns to shape
- The colour is even along the whole sprig, without pale patches
- Run your palm against the needles and no fibres or needles are left on it
Where the price difference comes from
A cast branch needs a mould and virgin raw material, while film needles are cut from a roll. You pay for a material that keeps its look and a crown that folds away after the season and opens the same way the next year.
Care that keeps the branches looking right
- Fold the tree tier by tier into its own box without twisting the branches
- Keep it somewhere dry with a steady temperature and put nothing heavy on top
- Remove dust with a dry or barely damp cloth; snow-tipped models with a dry soft brush
- Don’t overload the branches: each holds about 1 kg of decorations
Cast or PVC — which to choose?
If the tree will stand in plain view and be touched often, cast needles earn their keep: they are full, springy and don’t shed. For a detailed comparison, see the guide “Cast needles or PVC: what’s the difference”.
What it means when you buy
Dispatch in 1–3 working days by Nova Poshta free of charge; pay by card or cash on delivery. At the branch you inspect the box from the outside before paying, and can open and check the tree after paying, right there. 14 days for returns give you time to judge the branch texture at home; the warranty is 5 years.
How much does a cast-needle tree weigh?
The most popular height, 2.1 m, weighs 18–21 kg depending on the model. That is why large trees usually go to a Nova Poshta cargo branch rather than a parcel locker.
Can I order a model that is out of stock?
Yes, as a pre-order: such a tree is dispatched within 2 weeks. Whether a model is in stock is shown on its product page.
How long does a cast-needle tree last?
The warranty is 5 years. Cast branches do not shed, so how long the tree lasts depends mostly on storage: a dry place, its own box and nothing heavy on top.
What heights are available?
The catalogue runs from 0.6 to 4 m. To pick a height for your room, take 20 cm off the ceiling height: that margin keeps the top from pressing against the ceiling.