Everything you want to know about making displays with foam!

 

Expanded polystyrene blocks (EPS) is one of the most versatile materials available. At Foam Graphics we have the ability to CNC route and Hot Wire cut this material into any shape and thickness. 

Up to 2 inch EPS can be digitally printed on our UV presses and accurately cut to shape on digital routers. If a more vibrant and durable print is desired we can laminate a hard surface print to the face of the foam in any thickness. 

We stock foam in master billets (blocks) that are 44" x 48" x 96". These billets have a density of 1 lb per cubic foot. We can cut these blocks into sheets from .25" to 44" thick. Pieces can also be glued together to create giant letters and displays. 

Frequently asked questions about EPS foam

How do we make a standing foam letter? 

The taller the letter, the thicker the letter needs to be. We suggest a minimum of 2 inches in thickness for standing and as the letter gets taller increase the thickness. When you order a standing letter we can provide an acrylic base that you will adhere to the bottom of the letter with supplied silicone. Each letter will have its own separate base so you can customize letter spacing and placement.

Does EPS foam hold up well outdoors and how long will they last?

The foam is moisture resistant. However, we only recommend our displays be used outdoors temporarily. If you handle these displays carefully and store them properly indoors they can be reused many times. Since foam is such a lightweight material if it is handled without care they will dent or scratch easily. 

How big can we make foam letters and displays?

Foam can be assembled with adhesives which makes the size only limited to how you are going to get your display. If we are shipping your display we limit the size to 46". If you have the ability to pickup your display from our Birmingham, Alabama location you are only limited by the size of your vehicle. As always, feel free to reach out to our team if you have a special project in mind! 

Can I customize my foam display with a print or paint?

We have 2 processes for printing to foam. Foam up to 2" thick can be direct printed single or double sided on our UV flatbed printers. After printing they are digitally cut to shape on our routers. We can also print directly to a smooth sheet of plastic (.040 polystyrene). This print is then laminated for protection. Once the print is ready it is laminated onto the foam display. This process results in a higher quality print that is better protected form scratching. Latex primer and paints can also be used to customize your display.