Category Archives: Styrofoam letters and logos

How To Make Styrofoam Letters

Polystyrene Letters, Styrofoam letters and logos

Creating styrofoam letters using a hot wand tool and a card template can be a fun and creative craft project. Here’s a step-by-step guide to help you get started:

Materials you’ll need:

  1. Styrofoam sheet or block
  2. Hot wand tool (also known as hot wire foam cutter)
  3. Cardstock or thick cardboard to create the template
  4. Pencil
  5. Ruler
  6. Masking tape
  7. Cutting mat or surface

Step-by-step instructions:

  1. Prepare your design: Decide on the letters you want to create and sketch them on the cardstock or thick cardboard. Use a pencil and ruler to draw the letters, making sure they are the desired size and font style. You can print out fonts from your computer and trace them onto the cardstock if you prefer.
  2. Cut out the template: Use scissors or a craft knife to carefully cut out the letters from the cardstock. These templates will serve as a guide for cutting the styrofoam.
  3. Secure the templates: Place the cardstock templates on top of the styrofoam sheet or block, positioning them where you want the letters to be. Use masking tape to secure the templates to the styrofoam, ensuring they don’t move during the cutting process.
  4. Heat up the hot wand tool: Turn on your hot wand tool and allow it to heat up according to the manufacturer’s instructions. The hot wand will cut through the styrofoam cleanly, so make sure to handle it with care to avoid burns.
  5. Cut the letters: Once the hot wand tool is hot and ready, carefully and slowly trace around the edges of the cardstock templates with the hot wand. The heat will melt through the styrofoam, allowing you to cut the letters smoothly. Keep the wand perpendicular to the styrofoam surface to get clean cuts.
  6. Remove the templates: After cutting out all the letters, gently remove the masking tape and lift off the cardstock templates.
  7. Refine the edges: If needed, use the hot wand tool to smooth and refine any rough edges on the letters.
  8. Personalize and decorate (optional): You can leave the styrofoam letters as they are or paint them with acrylic paints to add color and personality to your project. You can also add other decorative elements like glitter, beads, or fabric to make the letters stand out.

Remember to work in a well-ventilated area, and be cautious while handling the hot wand tool to avoid any accidents or injuries. Styrofoam can release harmful fumes when cut with a hot tool, so ensure proper ventilation or wear a mask if necessary.

With this guide, you should be able to create beautiful styrofoam letters using a hot wand tool and card templates. Have fun with your project!

Big Freestanding Logo

3D Logos, Styrofoam letters and logos, ,

Large freestanding logo made from Styrofoam. Size of logo 1300mm x 510mm x 100mm thick. Painted in 5 colours matched to pantone colours. Logo hand painted to a matt finish using Dulux vinyl matt emulsion paint.

logo was used at an celebration event at a business office meeting, the logo was then fixed to a wall as an office wall logo display.

big-freestanding-logo-1300x520x100

Styrofoam logos can be made in various sizes up to 600mm high. Styrofoam is a high density version of polystyrene. Once it is painted it looks similar to painted MDF or painted plaster.

We keep sheets of 600mm x 2400mm in stock that we use to cut our logos from. Styrofoam logos and letters may be cut in various thickness from 25mm, 50mm, 75mm, 100mm, 150mm. Styrofoam may also be cut to a specific thickness such as 10mm thick or 20mm thick if required.

How To Make XPS Foam Letters Look Smooth And More Solid

Styrofoam letters and logos

To make xps foam letters look smoother and more like painted wood.

The process is straight forward but time consuming. Not viable commercially but can make an interesting project for creative folk.

First buy the letters already cut to shape on ebay or elsewhere.

Sand the letters to shape with a medium or coarse grade sand paper.

Use a paint brush to apply three layers of water proof PVA allowing each layer to dry.

Sand the surface smooth with wet and dry sand paper 180 grid.

Paint the surface with vinyl matt emulsion and the result is quite convincing.

Hand carved and sanded Styrofoam Letter.