Why we use EPS Foam at VFX to create props, 3D Elements, and 3D Signs

We’ve been asked why we use EPS Foam at VFX.  Why not use wood or other materials to create custom props and signs?  The answer is simple.  We mainly use EPS Foam because it comes with characteristics not normally found in other materials and can easily be shaped and molded into anything using our hot wire cutters and CNC machines.  Most people aren’t aware but EPS Foam is used in many different applications around the world.  You would be surprised at how many applications there actually are?

After a quick search online, I found a few different uses for this material:

  • 3D Signs
  • Advertising Props
  • Architectural Shapes and Designs
  • Balustrades
  • Building Insulation
  • Bridge and Roadway Coatings
  • Church Play Designs
  • Columns, Caps, Bases
  • Concrete Voids
  • Coolers
  • Cosplay
  • Custom Shapes
  • EPS Geofoam Blocks
  • Flotation
  • Holiday Displays
  • Insulated Concrete Forms
  • Insulated Wall Panels
  • Monuments and Monument Signs
  • Movie and TV Props
  • Museum and Zoo Exhibits
  • Packaging
  • Parade Floats
  • Pipe Insulation
  • Slab Insulation
  • Surfboard Blanks
  • Theme Park Props
  • Wall Art


One of the best things about EPS Foam is that when coated with Polyurea, it creates a very impact resistant and durable product that will last a lifetime if handled properly.  There are also water resistant versions of Polyurea used in coating swimming pools as well as several versions available for indoor and outdoor use. If you’re not familiar with Polyurea, it’s a type of elastomer that is a two part mixture that when combined, creates a very strong bond.  Taken from the Polyurea Wikipedia page: “Its (Polyurea) fast reactivity and relative moisture insensitivity made it useful for coatings on large surface area projects, such as secondary containment, manhole and tunnel coatings, tank liners, and truck bed liners. Excellent adhesion to concrete and steel is obtained with the proper primer and surface treatment. They can also be used for spray molding and armor.[fusion_builder_container hundred_percent=”yes” overflow=”visible”][fusion_builder_row][fusion_builder_column type=”1_1″ background_position=”left top” background_color=”” border_size=”” border_color=”” border_style=”solid” spacing=”yes” background_image=”” background_repeat=”no-repeat” padding=”” margin_top=”0px” margin_bottom=”0px” class=”” id=”” animation_type=”” animation_speed=”0.3″ animation_direction=”left” hide_on_mobile=”no” center_content=”no” min_height=”none”][1] Some polyureas reach strengths of 6000psi (40MPa) tensile and over 500% elongation making it a tough coating. The quick cure time allows many coats to be built up quickly.” [1]

There’s a great video from Discovery that shows the impact resistance and durability of Polyurea when a coating is sprayed on certain materials.  Here’s a link if you would like to view the video: https://www.youtube.com/watch?v=aR4eRpekjnY

What sets our company apart from most traditional sign and prop companies is that we use state of the art machinery to create your piece.  We have the ability to use 3D scanners to scan, scale, modify, and produce products.  We have hot wire cutters that will allow us to create signs, letters, and more.  We use 3D modeling programs to instruct our CNC machines on how to cut and carve anything you can imagine exactly to your specifications with very tight tolerances.  We also utilize a 28’ paint booth to coat, prime, paint, and clear coat your product to your specs.  All of these machines translate into savings over traditional methods since we can reduce the manufacturing times immensely.

If your company or organization needs wall art or architectural elements, 3D signage, props to attract customers to your booth or event, or something unique to use for photo opportunities, feel free to reach out to us for a quote.  We’re already working on projects ranging from cosplay props to 3D signs to themed structures and would love to get the opportunity to speak to you about your upcoming project.

For more information, feel free to visit us at:


[1] https://en.wikipedia.org/wiki/Polyurea[/fusion_builder_column][/fusion_builder_row][/fusion_builder_container]