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Dimensional Foam Stage Letters Logos and Signs

Fabricators of signs, logos and dimensional letters are challenged by different types of materials to choose from, including foam, wood, plastic, PVC, acrylic and metals. It seems that most sign shops and fabricators are moving into the use of foam due to its light weight characteristics, its ease of cutting, carving and handling, the possibility of hard coating it as well as its affordability. Foam letters, logos and signs can enhance the character and depth of a company message and facilitate recognition for its brand.

WeCutFoam specialized in dimensional foam stage letters logos and signs


custom stage foam letters for company event and tradeshow
Custom foam letters

Foam is all around us. There are countless products made of foam, specifically Styrofoam (also known as EPS or Expanded Polystyrene) from the crown moldings in your home to the exhibit you just saw in the museum or the cool sign on the store you just shopped at. But why would a fabricator choose to use foam when clearly, he has other choices of materials, such as metals, aluminum, plastics, PVCs Acrylics or wood.

WeCutFoam specialized in dimensional foam stage letters logos and signs

Theater Stage Exhibit from Styrofoam
Theater Stage Exhibit from Styrofoam

What Can Dimensional Styrofoam Letters be Used for?


Dimensional lettering can be used as directional signage, attached to a building, office entrances or on walls for branding a message. Fabricator and sign shops have been using various materials to create dimensional foam stage letters logos and signs for retail stores, companies, stages, weddings, trade shows, conventions and for any event. But imagine making letters from metal to go on a stage. Metals and wood are considerably heavy and are inconvenient for transportation and for handling when moved from one place to another. Wood can yield a great finish look, yet is heavy as well and takes a great amount of time to work with. And plastics and PVCs are not an easy material to shape and machine. Therefore, more and more fabricators are now using foam, which is a lightweight substance as a source for creating large dimensional letters.


Custom Large Styrofoam Letters
Custom Large Styrofoam Letters

Different Allpications of Foam Letters


There are many ways in which the dimensional letters can be created. They can be left as raw white material if called for. They can be covered in matte, semi-gloss or gloss finish. The letters can be painted with specialty paintings to resemble wood, or with Faux bronze-like paint to add a metal look. They can be laminated, covered in vinyl, in fabric or even be illuminated in the back to add a light effect to them. Acrylic can be laminated in the front of the letters to match a specific logo color or to make a sign look colorful.

WeCutFoam specialized in dimensional foam stage letters logos and signs


Large Foam Letters covered in Vinyl
Large Foam Letters covered in Vinyl

Hard Coating - Durability Solution for Foam Letters

Looks like acrylic cut letters have become one of the most popular choices for indoor sign letters. The acrylic is cut using a laser cutter and yields a fairly precise cut. Still, foam is the most cost-effective solution for creating signs, logo, letters and props. Since the raw foam material itself is brittle and can be damaged by water, humidity, time and sun exposure they can be protected by being hard coated. Different types of coating can be used depending on the application and use needed. They can be covered with light coating such as epoxy or rubber coating, to medium coating that can be sprayed, polished or brushed on such as Styrospray1000 or a hard coat polyurea sprayed with a reactor spray gun. The coating not only protects the letters, logo or sign, but also providing it much longer durability - They can last up to a life time once coated.

WeCutFoam specializes in dimensional foam stage letters logos and signs.


Large Stacked Foam Letters
Large Stacked Foam Letters

Is There a Size Limit to Foam Products?


A block of EPS foam is typically 4 by 4 by 8 feet. Therefore, the most convenient size to create the project is up to 4 feet. However, there is no size limit while creating and fabricating letters. If they need to be larger they can be made in sections and glued together, and while sanding the glued pieces, the sim is almost completely eliminated. The letters are cut using a CNC hot wire foam cutting machine. The foam is used to add dimension to the letters.


Epoxy Hard Coated Large Foam Leter
Epoxy Hard Coated Large Foam Leter

Foam letters are a great option for instance, if you want depth on a lobby wall sign. They are actually 2D that can resemble a 3D project. By giving it enough thickness, they can be "stand alone" letters on a stage. For instance, a 4 feet letter can be fabricated at 6 inches thick to be able to stand on its own, or made with a base. The foam can be cut fairly fast. A few single strokes of the hot wire melting into the material can create a letter in no time. Another advantage to the foam substrate is that it is easy to cut, mold, shape, carve and sand to a smoother finish.


How to Support the Letters and Add Stability?


Round letters can be made flat at the bottom to hold their own. The fabricator can create a base to the letters, either from the foam material itself, from clear acrylic and/or from plywood, therefor serving as a great support. Weights can also be placed inside the foam itself to hold the weight of the letter so that it does not tip off. If the letters need to be suspended, then clear acrylic can be placed at the back of the letter to attach it to the one next to it, creating a floating-like effect. To add even more stability, a double-sided tape can be put at the bottom opf the letters binding them to the floor or the stage and If they need to be hung from the ceiling, then eye hooks can be placed. In case they are bigger and heavier, metal rods and suspensions can be placed in them to add to the construction or heavy-duty hooks can be placed.


Large Foam Letters for NFL with Base
Large Foam Letters for NFL with Base

In Conclusion


Dimensional letters will help a company attract customers and convey a message in an attractive and aestethic manner. Yes, there are certainly a lot of choices out there and it can be confusing at times trying to sort them out. I would say that if you are budget conscious, but still want a quality looking sign, then foam letters, signs and logos are one of your best options. Dimensional foam signs, logos and lettering are a great way to enhance the character and depth of your message and to build recognition to your brand.


Learn more about fabricating foam letters on our website page


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