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Large Foam Letters

3d letter
foam letter
3d sign

3D foam letters are the future in advertising!

3D foam letters are proven to be 10 times more effective in attracting visitors to your event or business than any traditional methods of advertising.

Our custom large foam letters and 3D displays are the most innovative way to brand your company at exhibitions, trade shows weddings and events.

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All our letters are made from our

RHINO FOAM is specially made from High Density Expanded Polystyrene. It is a rigid, closed cell foam specifically used for applications where durability is required. RHINO FOAM properties have a high compressive strength, is light weight, inert, and is the ideal substrate for 3D letters and displays. Our RHINO FOAM letters and displays are the strongest on the market, extremely cost-effective,and the most versatile.

Our Work

bottle props
christmas event

Bold Messages

Large letters are ideal for making a bold emphasis on a brand, product, or message. Most often when thinking of large letters, smaller sizes come to mind. In reality, if you want a 6′, 10′, or 20′ tall humongous letters – we can do it! Adding interesting design aspects by having extreme thicknesses are possible.

Social Media Effectiveness

With today’s fabrication technologies, simple letters can be turned into pieces of art with vibrant colors, airbrushing, hard coating and special painting techniques. Combining structural elements with the letters can bring some interesting focus on the letters and the associated message. You are only limited by your imagination.

sign noni


At trade shows, these huge letters serve as a magnet to attract large crowds and to stand-out amongst myriads of other trade show booths. Retail stores can use them for visual marketing and product branding. Special events can use large letters to clearly identify the main message points. The size of the project doesn’t matter, we have the capabilities, resources, and capacity to deliver.


Need a 12′ tall x 80′ long x 6′ deep word created? – no problem! We can build extremely large letters and numbers. They can be built with bases or self-standing. They can be built with internal structures for added strength. Various hard coat finishes, painting, and airbrushing are all available.


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

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.

props doTERRA

Companies We've Worked With​

disney logo
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.