Cutting Low Cost Foam Core Letters - Foam Board vs. Styrofoam

When customers with a limited budget request signs, logos, and letters, a cost-effective option is to create them from foam board (foam core).

TEDx sign fabricated from foam core foam board

Foam core, also referred to as foam board, has numerous applications, such as signs, logos, letters, displays, arts and crafts, home decor, wall art, architectural models, backdrops, and more.

This material is versatile, lightweight, and durable, making it easy to cut. Its affordability makes it an excellent option for customers on a tight budget.

Its light weight allows for easy transportation, setup, mobility, display, and storage.

Foam Core Foam Board 1/2" thick

The foam core is usually coated with paper on at least one side. It cannot be cut using a CNC hot wire foam cutter because the wire could burn and melt the material and its edges. We utilize an oscillating knife cutting machine to achieve smoother corners and edges on the foam core.

Oscilating Knife Cutting Machine

Why do we offer low cost foam board letters, signs and logos?

Foam core is among the most affordable materials for printing and displays.

It works well for short-term projects, but it may not be suitable for outdoor use, long-term durability, or for multiple events.

If you leave a foam board exposed to the sun or rain, it can become discolored, disintegrate, or warp, and it is also sensitive to moisture.

It is ideal for temporary events rather than as permanent outdoor displays.

In situations where an outdoor project is required, or one that needs to be long-lasting, Styrofoam could be the preferable choice due to its durability. Nonetheless, foam core remains a rigid and durable option, just a thinner option.

foam board vs styrofoam letters cutting

foam board vs styrofoam letters cutting

When deciding whether to use Styrofoam or foam core for creating signs, logos, and letters, the choice primarily depends on the customer's budget.

Although Styrofoam (also referred to as EPS / Expanded Polystyrene) is what we cut most, foam core can serve as a cost-effective alternative for our customers.

The material cost of foam core is lower, and the knife cutting process is quicker compared to cutting Styrofoam with our CNC hot wire foam cutter.

Low cost foam core letters

Foam board letters by WeCutFoam

Foam board letters by WeCutFoam

The foam core (foam board) measures 4ft x 8ft with a maximum thickness of 0.5", whereas Styrofoam can be cut to much thicker dimensions. Therefore, aesthetics should be considered when comparing the two.

Additionally, when we need to join pieces together, we use a hot glue gun for the foam core pieces, whereas we use epoxy glue for the Styrofoam.

Cutting letters from foam core foam board with triangular support

Both materials are usually available in white and can be painted with acrylic paints and sanded if necessary; however, the foam core features a smoother finish.

We can enhance stability by attaching triangular supports to the back of the letters with a hot glue gun. Alternatively, we can include the triangles inside the box for the customer to glue themselves.

Low cost TEDx letters with triangular support

Low cost foam board letters and other products from this material is perfect for business or school presentations, advertising and branding companies, trade shows, event decor, backdrops, photo shoot and any application where a lower budget is a consideration.

Low Cost Foam Core Foam Board TEDx Sign

#foam #foamcutting #foamcuttingservices #foamboard #foamcore #lowcostletters #lowcostsigns #signs #letters #logo #logos #cnc #cnccutting #lowbudgetletters #TED #TEDx #TEDtalks #TEDxtalks #TEDxorganizer #TEDxevent foamcoreletters #foamboardletters