Polystyrene letters, also known as foam letters, are three-dimensional characters made from expanded polystyrene (EPS) or extruded polystyrene (XPS) foam. They are popular for signage and decorative applications due to their versatility, affordability, and lightweight nature.
Key characteristics
- Material: The letters are cut from large blocks of polystyrene foam using computer-controlled hot wire cutters (CNC). For higher quality or smaller designs, a denser XPS foam may be used for a smoother finish.
- Customization: They can be produced in any font, size, and thickness, from small tabletop decorations to giant freestanding letters up to two meters tall.
- Finishing: While often supplied as plain white foam, they can be painted, coated with a protective sealant, or faced with materials like colored acrylic, Foamex, or even a sand-coated texture for a masonry effect.
- Weight: Because the foam is 98% air, even very large letters are light enough to be easily moved and installed by a single person.
- Durability: Their durability depends on the intended use. They are robust for indoor, short-to-medium-term applications. For long-term outdoor use, they require protective coatings to prevent damage from UV rays and rain.
Where are they used?
Polystyrene letters serve a wide variety of purposes, particularly for temporary or eye-catching displays.
For business and branding:
- Event signage: Companies use them for promotional events, product launches, festivals, and fundraisers to display brand names, hashtags, or logos.
- Retail and window displays: They are an affordable and effective way to create seasonal or promotional messages in storefront windows or within a shop.
- Exhibition stands: Lightweight and easy to transport, foam letters help trade show booths stand out from a distance.
- Office and reception decor: They are used as permanent interior signage for company names and branding, often with a high-end finish like a colored acrylic face.
For personal and event decoration:
- Weddings and parties: Common uses include giant freestanding “LOVE” letters, initials for engagement parties, or custom numbers for milestone birthdays.
- Photo shoots: Their lightweight and three-dimensional nature make them ideal props for school, university, and private photo shoots.
- DIY crafts: Smaller polystyrene letters are available for hobbyists to paint, glitter, or decorate for home and holiday decor.
- Nursery and bedroom decor: They are a popular choice for personalized wall letters and signs.
For theater and education:
- Set design: Their ease of cutting and customization makes them perfect for creating props, backdrops, and scenery for film and theater productions.
- Educational displays: Schools and museums use them for educational exhibits, interactive displays, or wayfinding