How Much Weight Can You Hang From A Suspended Ceiling Why Use Foam Material to Fabricate Dimensional Letters, Logo or Signs

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Why Use Foam Material to Fabricate Dimensional Letters, Logo or Signs

Foam is all around us. There are countless products made of foam, specifically Styrofoam (also called EPS or expanded polystyrene), from the crown molding in your home to the exhibit you just saw at the museum or the cool sign at the store you just shopped at.

Why would a manufacturer choose to use foam when there are other choices of materials such as metals, aluminum, plastics, PVC acrylics or wood?

Dimensional letters can be used as directional and architectural signs attached to buildings, office entrances or walls to convey a message. Factory and Sign Shops use a variety of materials to create dimensional letters, logos and signs for retail stores, companies, stages, weddings, exhibitions, conventions and any event. But imagine making letters out of metal to go on stage.

Metals and wood are quite heavy and inconvenient to transport and handle when moving from place to place. Wood can give a great finish, but it’s also heavy and takes a lot of time to work with. And plastics and PVC are not easy materials to shape and process. Therefore, foam, a lightweight material, is now used by more and more manufacturers as a source for creating large-sized letters.

There are many ways to create dimensional letters. If necessary, they can be left as white raw materials. They can be covered with matte, semi-gloss or glossy paint. The letters can be painted with custom prints to look like wood, or with a faux bronze like paint to add a metallic look. They can be laminated, covered with vinyl, fabric, or even backlit to add a light effect to them.

Acrylic can be laminated to the front of the letters to match a specific logo color or to make the sign look colorful. Acrylic die cut letters seem to be becoming one of the most popular choices for indoor sign letters.

Acrylic is cut using a laser cutter and gives a very precise cut. However, foam is the most economical solution for creating signs, logos, lettering and props.

Since the raw foam material itself is fragile and can be damaged by water, humidity and sunlight, a coating can protect it. Different types of coating can be used depending on the application and usage needs.

They can be coated with a light coat of epoxy, Styrospray1000, which can be sprayed, polished or brushed on, or a reactor-sprayed solid polyurea. The packaging not only protects the letters, logo or sign, but also ensures its durability – once coated, they can last a lifetime.

EPS foam block is usually 4 by 4 by 8 feet. Therefore, the most suitable size for making a project is up to 4 feet. However, there are no size restrictions when designing and creating letters. If they should be larger, they can be divided into parts and glued together, and when smoothing the glued parts, the seam is completely removed.

The letters are cut using a CNC hot wire foam cutter. Foam is used to add dimension to letters.

Foam letters are a great option if you want depth on a lobby wall sign, for example.

They are actually a 2D that looks like a 3D project.

By giving it enough thickness, they can become “individual” letters on stage. For example, a 4-foot letter must be at least 8 inches thick to stand on its own.

Foam can be cut fairly quickly. A few single strokes of the molten hot wire on the material can produce a letter in no time. Another advantage of the foam substrate is that it is easy to cut, mold, shape, trim and sand for smoothing.

Round letters can be made flat on the bottom to hold them in place.

The manufacturer can make the base of the letters from a foam material or acrylic, which is transparent, so it will be a perfectly invisible support.

You can also put weights inside the foam to support the weight of the letter so it doesn’t fly away.

If you need to hang the letters, you can use double-sided tape, for example, to hang them on the wall. If they are large and heavy, you can put metal rods and suspensions on them or put hooks to hang them from the ceiling.

Dimensional letters help a company attract customers and be attractive.

Yes, of course, there are a lot of choices out there and sometimes it can be confusing trying to sort through them. I would say that if you are budget conscious but still want a quality looking sign, foam letters and logos are one of your best options.

Dimensional foam signs, logos, and lettering are a great way to add character and depth to your message or logo and promote your brand.

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