We started out by cutting the "G" letter out of high density Urenthane foam, also known as tooling foam. The letter was machined using our CNC router milling machine.
We then then used Bondo Agent to fill in any cracks or scratches the material might have gad, so will be as smooth as possible. It is a body filler bumper repair putty, used mostly in the automotive industry.
We sprayed the Urethane foam letter with Filler Primer spray, again materiel mostly used in automotive industry. It fills in any imperfections, so assists the Bondo in filling any cracks in the foam material.
This is how the Urethane letter looks like after pasting the Bondo and spraying the filer.
We then painted the letter in black as required by the logo
As soon as we finished with the "G" we went on to fabricate circular foam holder. We cut EPS foam on our CNC hot wire foam cutting machine, sprayed it with Polyurea hard coat and sanded it.
The last phase was to paint the holder yellow and red, then to glue the "G" at the center. We then added eye hooks so that the logo can be hanged from the ceiling.
Here is a video showing the completed fabricated Logo