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Foam Sculptures & Props

pre cast
IMG_0217-2-1
3d popsicles

With Foam Fab, your only limit is your imagination!

Our team of skilled craftsmen can create any custom foam sculpture or prop for your project.

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Sculptures & Props

Applications:

books prop

Our Work

bottle props
christmas event

Bold Messages

Large 3D sculptures and props are ideal for making a bold emphasis on a brand, product, or message.

Fabrication Technologies

With today’s fabrication technologies, we can 3D scan small scale models and scale them to any size. We also specialize in various hard coating and special painting techniques.

themed
haruharu
sign noni

Branding

At trade shows and events, large 3D props serve as a magnet to attract large crowds and to stand-out among myriads of other trade show booths. Retail stores can use them for visual marketing and product branding.

Frequently Asked Questions

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.

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.

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.

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

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.

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.

Do you have a question we didn‘t answer? Don’t hesitate to contact us at 1-801-802-0617 or info@foam-fab.com.

Foam Fab has delivered projects around the world.

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.

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props doTERRA

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.

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.

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.

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.