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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.

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Textured 3D Letters

Textured 3D Letters

Textured 3D Letters

Polystyrene letters and logos with a masonry textured face. Letters are made from expanded polystyrene or xps foam, they are then coated in a layer of fine grade sand and then painted with masonry paint.

Letters that have been coated in sand may be used out side for permanent signage as long as they are away from people touching them because they are still primarily made from polystyrene.

textured sign letters
textured sign letters
textured display letters
masonry textured display letters

When letters are larger than 300mm high the letters would also be given on layer of fibreglass on the face and back to improve structural integrity before coating in fine grade sand and then masonry painted.

textured 3D letters would lend themselves to the Arts and crafts shop signs as well as being suitable for garden centres.

textured 3d letters
textured 3d letters

Textured 3D Sign Letters are a unique way of producing sign letters and display letters and logos. Get creative.

textured
textured

5mm Thick XPS FOAM

Polystyrene Letters

5mm thick XPS foam sheets ideal for model making and war gaming scenery.

XPS foam can be cut with a knife or cut with a electric hot wand tool, it can be sanded as well as burnished into shape.

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