Foam boards were sent from God for the sign person. They have become a standard for mounting and fabrication in the graphic arts industry. Ranging from inexpensive products like Fome-Cor to high-end leaders like Gatorplast, we still haven’t seen the end of innovations in this arena.

Range of Options

Generally speaking, foam boards are comprised of a rigid foamed polystyrene or polyurethane core with smooth layers laminated over the outer faces. The foamed cores combine structural rigidity with light weight and the outer layers provide a smooth, hard surface for mounting prints. They are also available in acid-free variants for archival work. Some foam boards can also accept direct inkjet printing and most can be printed using a UV-curing flatbed. Others have adhesives already applied to one side for ease of print mounting.

Flame-Resistant Foam Board

Flame resistant foam boards, like LitePrint FR foam board from The Gilman Brothers Company, are highly recommended for trade shows and exhibitions where fire codes commonly demand the use of flame-resistant materials. Flame-resistant foam boards are designed to resist ignition and combustion while still maintaining all of the other characteristics of traditional foam boards.

Less-Expensive Foam Board

The least expensive and least rigid, foam core boards have clay-coated paper surfaces. Thicknesses are usually 1/4” or 3/16”. Mounting prints can be a little tricky as these boards compress easily. It is important for the laminator rolls to completely even top and bottom and for the top roll to descend evenly left to right. Experimentation will be necessary the first time to get the right amount of pressure.

Working with Foam Board

Some warping can be expected from the thinner less-rigid versions of these lightweight substrates, but they are very easy to work with. Gluing is accomplished with carpenters’ white glue or two-part epoxies. They can be folded and bent and they provide a very stable, smooth mounting surface. A utility knife is all that is needed to make clean, crisp cuts. A sharp blade is critical, combined with a metal ruler. Make multiple light cuts, not single, heavy cuts. Cutting with the knife completely vertical will also help to give clean edges.

Foam board die-cuts perfectly, leaving a "pillowed" edge that remains closed permanently. Foam-X Recovery has a unique manufacturing feature that allows the edges to stay open after die-cutting for those that prefer that appearance. As well, you can emboss or de-boss for clean, sharp designs and displays. Anybody doing a lot of work with foam boards would do well to consider acquiring some specialty tools like those available from FoamWerks Tools (Logan Products). They offer inexpensive aids that can increase productivity and production quality. Foam core boards cannot be cut with a conventional router, but there is a CNC attachment that can be used to cut foam core. It is called the Donek Tools Drag Knife and works much the same way as vinyl cutters do.

Structural Foam Board

At the top rung of the ladder are the structural foams like Kapa-Bloc and Gatorfoam. These panels are strong, structural, and moisture resistant. Exposure of unprotected faces to the sun has very little effect, however exposed foam edges will deteriorate and need to be protected. This can be done with plastic edge frames, or even a coat of latex paint (not an oil or lacquer based paint, they will melt the foam). Black foam products are generally not as durable outdoors as the white and craft finishes.

Dimensionally Stable

Some of these boards also feature exceptionally tough surfaces that resist dents and punctures. They are very dimensionally stable and also almost impossible to warp or bend. Coverings range from melamine resin-coated paper on Kapa-Bloc, to styrene on GatorPlast and even wood fiber veneers on the GatorLite. Unlike other lightweight products, thicknesses range from 1/4” all the way up to 2”. The thickness of the sheets adds extra dimension to the graphics. They also come in 5’ x 10’ sheet sizes for those oversize projects.

Fabricating

Fabricating with these products is a dream. They can be cut with table saws, routers, jigsaws or band saws. The edges never shred or tear like the less expensive variants. Final shaping of the soft core is easily achieved with sandpaper or files. Contact cement or carpenter’s glue both work well to join the pieces permanently. This makes them ideal for three-dimensional work and creative layering effects.

“Greener” Foam Board

Now you can also be relatively “green” with foam boards. For example, Duraplast Biodegradable is an all-plastic foam board consisting of a biodegradable polystyrene foam center, faced with waterproof biodegradable polystyrene liners. This foam board is also completely recyclable. The rigid foam board breaks down in landfills or composting environments in one to five years. The breakdown of the biodegradable foam board will not begin until the board is discarded. Many of the major manufacturers also feature environmentally friendly products that have been manufactured with non-toxic, sustainable materials.

Whether the requirement is light or strong, inexpensive or durable, permanent or temporary—there’s a foam boards solution for the job. But there are so many choices the only question is where to start.