Skip to content

Exhibits, Museums & Zoos

Our Work

Full-service Solution for High-quality Exhibit Pieces

Foam Fab provides professional high-quality exhibit pieces to a wide variety of clients, including Museums, Zoos, Theme Parks, Visitor Centers, Lobbies, Showrooms, Corporate Offices and much more. We team with Designers, Engineers, Artists and End-users who use their passion, expertise and versatility to develop fun and lasting exhibits. 

Foam Fab also creates engaging themes and play environments for kids and families. We work with clients from concept, to design, produce, and install based on the client’s vision, budget, and timeframe. The spaces we transform are areas in museums, churches, pediatric dental offices, hospitals, amusement parks, water parks, family entertainment centers, theme parks, and really any destination for families.

Get a Free Quote

For a quote, please provide dimensions, quantity, material type, a description, and a DXF, DWG, DWT, STL or STEP file (DXF preferred).

our mission

We understand that what we do takes a group of talented people working together to create something beautiful.

Foam Fab is your full-service solution for all your fabrication needs. Our mission is to build positive and lasting relationships with our customers by fabricating exceptional exhibits with a team of experts in ​their fields. We are devoted to bringing life to our client’s designs, one exhibit at a time.

Services include

  • Concept designs to full production and installation.
  • Interactive Exhibits
  • Custom Displays
  • Custom Casework
  • Specialty Laminates
  • Metal & Plastic Fabrication

...and

  • Model Fabrication
  • Scenic Painting & Finishes
  • Graphic Production
  • CNC machining 2D and 3D
  • Custom casework
  • Custom signage

Materials & Pricing

Foam Fab offers a variety of CNC routing services – both 2D & 3D.
​We can accommodate sheets up to 59” x 119” x 5”.

Materials: plastics, plywood, MDF, hardwood, sign foam (other materials can be accommodated, please ask)

For a quote, please provide dimensions, quantity, material type, a description, and a DXF, DWG, DWT, STL or STEP file (DXF preferred).

Price is based on machine time and material type.

Our Expertise

Fast Quotes

We know you need pricing fast. We provide quick turnarounds on our quotes.

Quality inspection

From concept to finish product, we will keep you informed throughout the production process.

Expedited service

From order to ready to ship, we make sure you will hit your project deadline.

Companies We've Worked With​

wendys-2-150x150
disney logo
Ted
Evermore park

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.

Get A Quote

Contact us about your next project. Get a Free Estimate Today. We are looking forward to helping your business standout!