Custom Large Foam 3D Letters, Signs, Props & Sculptures

Foam-Fab designs and builds eye-catching props, trade show displays, branded environments, and oversized product replicas that attract attention, drive engagement, and create unforgettable experiences.

Copy of Scottsdale Fashion The Cactus Collective-128

Copy of Scottsdale Fashion The Cactus Collective-127

What We Build

Custom Fabrication Solutions for Every Industry

Whether you're launching a product, exhibiting at a trade show, creating a themed environment, or planning a marketing activation, Foam-Fab can bring your vision to life.

Industries We Serve

Trusted by Agencies, Brands & Builders:

Rental Inventory

Need Something Fast?
Explore our growing inventory of rental props including:

Giant Beverage Cans
Cosmetic Bottles
Sports Props
Social Media Displays
Grand Opening Packages
Supplement Bottle
Giant Candy

Frequently Asked Questions

What file type is required to make a 3D Foam projects?

We can use most any major CAD or 3D file formats. If you don’t have a file and need help in design, we can help bring your idea to life.

What technology do you use for large 3D projects?

It can be a number of different technologies, individually or combined. These range from 3D Foam, 3D printing, CNC Cutting, fiber glass molds, sculpting, painting, airbrushing, laminating, vinyl printing, and woodworking.

What material do you use?

We match the correct material and fabrication process to your requirements in terms of presentation, size, and logistics. In our shop, we fabricate using different types of foam, wood, metal, resins, and acrylics.

What is the largest 3D project you can make?

There is no limit to the size of model. Logistics will be your only concern on an extremely large 3D projects.

What is the turnaround time for a project?

This depends on the details of the project itself as well as the scale of the project. We usually ask for three to four weeks from the time we take the order to when you will receive the model. Smaller projects will take less time. We understand that sometimes deadlines are tight and we can accommodate rush orders.

What features can a 3D project have?

We can make each project as detailed as you would like through sculpting and finishing with painting techniques that will give you project the look you expect.

Have additional questions?

Do you have a question we didn‘t answer? Don’t hesitate to contact us at 1-801-802-0617 or [email protected].

Worldwide Delivery

Foam Fab has delivered projects around the world.

Steps in Creating a Large 3D Project

There are many steps in creating a high-quality large 3D project and each project is different. We will cover four general steps we go through on each project.

1 Choosing

the correct fabrication medium: Most of our projects are created using foam or fiberglass or a combination of both. When working with foam, we typically use polystyrene foam, specifically Rhino Foam EPS. Polystyrene foam comes in common densities ranging from 1 lb. to 3 lb. 1.5-2 lb. density works well for the best compromise in affordability (lower density is cheapest), ease of use (lower density is easier to cut and manipulate), and durability.

3 Applying features

You can adhere smaller pieces of foam (that were easier to duplicate or carve as a stand-alone). There are many process to use to get textures and features needed to create the project.

2 Using foam

We work in our 3D modeling software to create the design then we manipulate the model to use our CNC hot wire cutting machines to cut the parts out then put the parts together with a strong industrial adhesive. For more detailed projects we will have our sculptors sculpt the foam “free-hand” to get the right details for the project. Sculptors will use for finer sculpting and sanding many different types of small hand tools for final finishes before hard coating.

4 Finish work

There are a lot of methods to finish off the project depending on a number of factors related to project requirements, such as final durability, weather-proofing, temperature, mobility, strength, making casts and flexibility. Typically, you need to seal the surface and apply protective coatings. These finishes may be combinations of painting, air-brushing, flat-to-glossy finishes, soft-shell, and hard-shell coatings, sealers, and fiber glassing. These can be from latex, acrylic, polyurea, polyurethane, and many others.

Testimonial

What Our Customers Say

The tire is incredible and your team completely crushed it.

Dan P

Sales & Marketing

Beautiful work and great communication

Yasmira T

Customer

Items delivered were perfect color and as expected. Well packed and high quality.

Rebecca

Purchaser

These letters are AMAZING!

Kristin

Sales Executive

Absolutely fantastic business to work with. Tyler has been extremely helpful and provided information related to everything. This helped me to understand their processes and their capabilities. I would highly recommend bringing your project to these guys.

Jonah