Polystyrene Signage

Polystyrene is a lightweight product used primarily for indoor or temporary outdoor signage. This durable material is ideal for the customer seeking cost effective signage. Typical applications include the following signage:

Menu boards
Special events
Directional and informational signage

Indoor point-of-sale
Temporary signage
Low-cost signage
Trade shows

Dimensional Foam Letters + Logos from Impact! Sign Letters is a cost effective solution for a wide variety of interior signage needs including corporate graphics, reception area and lobby signage, retail POP signage, special event signage, and tradeshow displays.

Foam Letters are extremely lightweight, and are available in a variety of thicknesses and finishes to serve all your signage and visual display needs. Choose from standard fonts and colors or let Impact!

Sign Letters replicate your custom logo and font, or PMS color.

Wire Cutting of polystyrene

Cutting polystyrene (or any other thermofusible material) with a hot wire is not in fact a direct mechanical action of the wire on the material, but rather the action of the layer of hot air surrounding the wire. Thus, there is normally no direct contact between the wire and the material. A good quality cut requires the correct adjustment of wire temperature and its speed of movement.

These parameters depend on the type of material used. The wire temperature has to be regulated according to its metallurgical characteristics in order to maintain mechanical strength. Too low a temperature will result in a cutting speed that is too low, whereas too high a temperature will very quickly burn out the hot wire

Preparing the Cutting Shape

The shape to be cut out is created in a vectorial graphic file using your preferred drawing software. We recommend the use of CorelDraw when preparing the cutting path to cut foam. As cutting polystyrene foam is simple but has its particularities, we found this software to be the most accesible both in terms of user interface and price. One should keep in mind that one cannot remove the wire from the polystyrene foam during the cutting so the path should be a continuous line with entries and exits to cut inside holes

Dura-foam Letters

Dura-Foam Letters are made from Gatorfoam ®, which is a structural foam, sandwiched between a hard facing, providing extra durability and a smooth surface. Dura-Foam letters can be used unpainted natural white or black or painted in a standard color or custom color with either a rich matte or semi-gloss finish.

Foam Letters with Metal Laminate Letters are made form real metal laminate, available in a variety of finishes, adhered to Gatorfoam ® and precision cut. The sides can remain unpainted, or be painted with matching metallic paint, or in any standard color or custom color with a matte or semi-gloss finish.