Category Archives: Polystyrene Letters

How To Make Polystyrene Letters

Polystyrene Letters

How to make polystyrene letters using a Hot Wand Tool

How to cut a 3D letter ‘A’, expanded polystyrene letters using a hot wand tool

Creating polystyrene letters with a hot wand tool is a popular method for crafting decorative signage and displays. The process involves using a heated wand tool to cut and shape polystyrene foam sheets into letterforms. Here’s a step-by-step guide to help you:

Materials you will need:

  1. Polystyrene foam sheet
  2. Hot wand tool (also known as a hot wire foam cutter)
  3. Letter templates (printed or drawn on paper)
  4. Utility knife or scissors
  5. Sandpaper (optional)
  6. Safety goggles
  7. Work gloves

Step 1: Prepare your workspace Choose a well-ventilated area with a sturdy work surface. Lay down a protective covering like a craft mat or newspaper to catch any foam debris. Ensure you have access to a power outlet for the hot wand tool.

Step 2: Design and prepare letter templates Print or draw the letters you want to create in the desired size on a piece of paper. Cut out the letters using scissors or a utility knife. Ensure the templates are accurate and neat.

Step 3: Prepare the polystyrene foam sheet Measure and mark the desired thickness and height of your letters on the foam sheet using a ruler and pencil. Use a utility knife or scissors to cut the foam sheet to the appropriate size. Make sure the foam sheet is flat and free from any creases or wrinkles.

Step 4: Heat up the hot wand tool Plug in the hot wand tool and let it heat up according to the manufacturer’s instructions. Ensure you wear safety goggles and work gloves throughout the process to protect yourself from hot foam and debris.

Step 5: Shape the foam using the hot wand tool Place the letter templates on top of the foam sheet and secure them with tape or pins. Turn on the hot wand tool and wait for it to reach the optimal cutting temperature. Slowly and steadily guide the hot wand tool along the outlines of the letter templates, pressing gently but firmly to cut through the foam sheet. Follow the templates precisely to achieve accurate letterforms.

Note: The hot wand tool’s heated wire will melt through the foam, so avoid excessive pressure that might distort the shape or create rough edges. Take your time and work carefully.

Step 6: Finishing touches After cutting out the letters, inspect them for any rough edges or imperfections. You can gently sand the edges with sandpaper to smooth them out if necessary. Be cautious not to apply too much pressure or heat to prevent melting or warping the foam.

Step 7: Clean up and display Once you’re satisfied with the shape and finish of your polystyrene letters, clean up the workspace by removing any foam debris. Your letters are now ready to be displayed. They can be painted, decorated, or attached to a backing board as per your design preferences.

Remember to always prioritize safety when working with hot tools and handle polystyrene foam carefully to avoid burns or injury.

Big 3D Numbers For Events

Polystyrene Letters,

Large painted polystyrene numbers. 1200mm high, 300mm thick, painted bright yellow for a business based in London.

big-3d-numbers


For your next big number project contact Arro Signs by email for a price. Numbers can be made up to 2400mm high by 300mm thick in one piece, even larger sizes would be supplied in sections because the sheet size for polystyrene is limited to 2440x1220mm.

Faux Concrete Signs and Letters for Displays

Polystyrene Letters

Faux concrete sign made from styrofoam, coated with a 2mm layer of gray limestone acrylic resin mix textured masonry finish. Made for short term outside use at a university campus.


 
The sign measured 3300mm by 450mm by 50mm thick.

The faux concrete sign concept was initially created for use on interior wall logo displays, used by various building and construction companies as well as interior designers and hair salons.

By using the correct glues and resin the signs become suitable for outside use. If we increase the amount of limestone resin coating on the styrofoam, the panels become even more durable and suitable for long term use outside. They would also make a good base panel for painting art panels or for sign writers who are looking for a masonry finish.

We have been working on coating the panels in sandstone, yellow limestone, and gray limestone.

Using the stone resin coating method we have also been producing faux concrete letters for interior free standing office displays and for use for commercial photo shoots.

The example above indicates a styrofoam sign coated in gray limestone acrylic resin masonry finish. The sign logo was fitted by the customer onto an office wall using silicone adhesive.

Large faux concrete display logo for office desk or office shelf display.

250mm high and 50mm thick.

Contact us for a quote.

All letters are custom made to order from styrofoam, coated in a thin layer of pigmented acrylic resin limestone. The letters in the image above were base weighted internally to allow the letters to free stand without rolling off a shelf or desk.

How to Send Us vector Artwork?

Polystyrene Letters

To set up artwork for cutting on our polystyrene cutting machines we require vector artwork. Artwork needs to be saved as an eps file with all fonts converted to curves.

If the artwork is in the form of a jpeg we will need to digitize the logo to make a vector artwork of it before we can cut it.

We use Corel Draw to make our vector artwork, there is also free software available on the internet that can be used for producing vector artwork such as Inkscape.

Large Foam Letters UK

Polystyrene Letters,

An Introduction To 3D Polystyrene Letters and Logos

Polystyrene Letters and Logos For Exhibitions, Shop Displays and Events.

Polystyrene logos and lettering custom made to order from 50mm high to 2000mm high, 25mm thick to 300mm thick, used for Exhibition Header Panels, Shop Displays, Events and Office Wall Logos and Wall Statements.

Contact: sales@arro-signs.co.uk

Natural white finish polystyrene letters are cut from sheets of STFRA grade expanded polystyrene,  the letters are then  cleaned ready to be supplied to the customer. Lettering is often painted by the customer using their own paint so as to match any existing paint work on other parts of an existing display. Customers sometimes use the lettering as a base to glue various other materials to them such as glitter or coloured paper, gems or precious stones or use the letters to cover in florists flowers or mosaic.

Please feel free to contact us by email: sales@arro-signs.co.uk or phone us on 01202 546540.

Polystyrene letters with a Painted Finish made from natural white expanded polystyrene and then given two layers of high quality vinyl matt emulsion paint. We use the Dulux paints because of their quality, customer service and their ability to match colours closely to Pantone.

Polystyrene letters With A Card Face give a smooth finish to the front of the letters. Available in gloss or matt. The letters are available with painted sides in a matt finish using vinyl matt emulsion.

Styrofoam Letters for Outside Use for short term outdoor events or permanent exterior use for shop signs. If the letters are required for short term use a we apply two layers of masonry paint. Letters are also suitable for permanent use outside with matt painted finish.

Digital printed Logos are mounted onto card or plastic and then fixed onto polystyrene. This process would be ideal for any exhibition or window display.
An example of a digital printed vinyl logo mounted onto 2mm foam PVC then fixed onto 75mm thick painted polystyrene.

Large Polystyrene Letters are used for shop window displays and business events and celebrations, they have also been used in Offices as visual logo displays. Other uses for large lettering includes commercial photo shoots and website promotions.

Large 3D Logos are used for shop displays in Department Stores.
Example of a Logo for a designer Kitchenware Business, 1700mm x 700mm x 400mm thick, painted grey with white Matt face. Designed for hanging from a ceiling in a London Department Store.

joseph-joseph-3d-logo-1700mm-700mm-400mm-thick-double-sided

Big 3D Numbers for use in shop displays, may be fixed to walls or for use as freestanding numerals on shelving units within shop display systems. An effective way of visual communication.

The example shows a number  three, 250mm high, 50mm thick, painted orange matt, designed for free standing  on shelving units within retail department stores.

Polystyrene logos For Office wall Displays are used for exhibition displays and are also used for shop window displays and in-store displays and office wall displays.

3D Polystyrene lettering for Events

'TEDxImperialCollege'

How To Make A Faux Stone Boulder

Fake Boulders, Polystyrene Letters,

How to make a faux boulder for shop displays or for use in the garden as a large garden feature.

polystyrene boulder
faux boulder

To make a faux boulder I would advise you to first make a miniture one out of modelling clay or go to the beach and pickup a pebble from the beach to use as a guide when making the faux boulder.

Take one large block of polystyrene or glue sheets of polystyrene together to make a block of poly. Glue poly together with contact adhesive.

Carve the block into a rough shape using various hand saws, and rough sand paper.

Cut out a hole in the bottom of the shape and fill it with resin to make it have a heavy base and this will make it stand up by itself and not fall over.

Coat the polystyrene in layers of paper mache using water proof PVA, must be water proof PVA and not the standard PVA. Coating the polystyrene with water proof PVA and sand is also effective. You can also coat the poly with quadraxial fiberglass and jesmonite AC100 which is what we did on this project. Adding a few layers and allowing it to cure before finishing the top layer with a coloured jesmonite. To colour the jesmonite use iron powder mixed into the jesmonite. Once the resin is cured use sand paper on the surface to make a smooth finish and remove any brush marks.

3D Logos and 3D Letters For Office Wall Displays

Polystyrene Letters,

Wall Display Letters and Wall Display Logos. 3D characters made for fitting onto walls, made from polystyrene or styrofoam. Letters and logos may be made in any font or design up to 1000mm high by 150mm thick. Characters may be covered in vinyl faced card or matt vinyl emulsion painted.


For advice and a price contact us by email to sales@arro-signs.co.uk