3D Polystyrene Letters, Signs and Logos

We can produce letters from as small as 50 mm high to well over 3 metres.
Thicknesses vary depending on structural needs and intended use — typically 25 mm up to 500 mm or more.
You can use almost any font, or even supply your own artwork. Very fine or delicate fonts may require small modifications or support structures to maintain stability.

Over more than 50 years we’ve developed our own in-house systems for cutting polystyrene letters, producing a smoother surface finish than standard methods. On most sizes we can also remove the centres of letters such as “O” and “B” without cutting through the face, giving a cleaner appearance.
We combine these techniques with traditional CNC hot-wire cutting.
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Natural (plain polystyrene): The natural white finish of the foam, which may show a slight bead texture.

Plain XPS: A denser, closed-cell material (often called Styrofoam or “blue foam,” though it comes in various colours including white). It gives a much smoother cut — ideal for high-quality small letters or interior signage.

Painted: We offer a full painting service using both interior and exterior paints.

Faced: Options include Foamex, vinyl card, MDF, or acrylic — giving a smoother or more rigid face, or allowing for printed finishes.

Protective coatings:
• Water-based coating: Strengthens the letters, almost eliminates chipping, and improves flame resistance. It also serves as an excellent undercoat before painting — ideal for most uses.
• Polyurea coating: Creates an exceptionally strong, impact-resistant finish — perfect for permanent or heavy-use installations.

Yes — provided we know in advance, we can apply suitable coatings and paints so your letters perform well outdoors.

Uncoated white polystyrene requires careful handling, but the coatings mentioned above strengthen it considerably. We can also add thin MDF faces or backs for extra rigidity.
If maximum strength is required, take a look at our wooden letters range.

Wall mounting: Adhesives, double-sided tape, Velcro, or fixings.

Freestanding / floor letters: Some letters will stand alone, but for stability we recommend base boards or plinths, which can be weighted or fixed down.

Stacked or multi-level displays: Achieved with clear acrylic or other support materials.

We’re always happy to advise on the best installation method for your project.

Lead time depends on the size, finish, and quantity ordered.
As a guide, a set of around 6–10 letters at roughly 1 m high, cut and painted, would usually be dispatched within 5–7 working days.
We can often fast-track urgent orders in just a couple of days, depending on complexity and workload.

They are extremely lightweight — even large letters can usually be handled by one person.
Exact weight depends on size, thickness, and coatings. We can provide weight estimates with your quotation.

Yes — we can match colours using Pantone, BS, RAL, HEX, RGB, or paint references.
RAL or paint numbers give the most accurate results. Pantone shades are intended for ink, but we have extensive experience achieving close paint equivalents.
If a perfect match requires a cellulose-based paint, we’ll apply a special undercoat to protect the polystyrene and discuss the options with you during quoting.

Yes — with appropriate care and coatings, the letters can be reused many times. It’s important to give us as much information as possible when ordering, so we can advise on the best materials and finishes for your intended use.

Plain uncoated polystyrene letters, and their packaging, can be recycled at many facilities across the UK. We can often arrange collection, though transport costs apply and are quoted on a job-by-job basis.

Once the letters are coated, recycling becomes more complex as the coating needs to be removed before the core material can be reused or recycled. This is a service we can offer, also priced on a job-by-job basis. We only quote for recycling letters we have produced ourselves, as we need to know exactly what materials we’re working with.

Yes — if your letters are showing signs of wear, we can quote to refurbish them. This typically involves filling minor damage and recoating the surface. Severely damaged letters may need to be recycled and replaced.