Competition for the attention of customers in malls, restaurants, and other commercial venues can be fierce. Even with parades and sporting events, standing out and making a stunning first impression can be difficult. That is where Custom Engineered Arts takes the lead making your business, tournament, or private function memorable and captivating. We quickly create large scale sculptures in practically any shape and form that you can dream up from a material that is strong and inexpensive: EPS foam. This blog will discuss the facts about EPS foam and how it is ideal to use foam for large-scaled sculptures.
Foam Sculptures are Lightweight Yet Structurally Strong
The specific foam sculpture material utilized for our products is expanded polystyrene (EPS), or better known as styrofoam. This material is ideal for foam sculptures for many reasons. It is extremely light compared to other materials. The EPS that we use can be cut, sculpted, shaped, and detailed very quickly at a lower cost than other materials.
Additionally, even though EPS is very light, it has a very strong structural integrity withstanding compressive force of up to 1,580psi. Foam of that strength is used in highway construction, foundation support and bridge abutments. With that kind of strength and stability, smaller blocks of EPS can be molded and fit together easily to fashion massive custom sculptures of almost any size that don’t weigh a lot and don’t lose structural integrity. EPS foam sculptures can last decades.
Foam is Cost-Effective for Large Sculptures
When looking to make 3D EPS foam sculptures for a trade show, advertising, or a wedding, foam is quite cost effective for many reasons:
- 98% Air – Foam is made with as little as 2% material and 98% air. This makes it an exemplary lightweight sculpture material.
- Quick – Molding and carving styrofoam is very quick, and sculptures and other items can be made in a fraction of the time of other methods such as cast molding or injection molding.
- Shipping Costs – Because of the lightness of the material, transporting foam sculptures is simple and without the need for heavy machinery.
- Recyclable – Foam sculptures are 100% recyclable. To make your life easier, Custom Engineered Arts has the option to disassemble and recycle your props and sculptures in a manner friendly to the environment.
Foam Sculptures are Easy to Install and Transport
Another benefit of foam for sculpture fabrication, is foam, depending on its density, typically weighs between 11 – 35kg per cubic metre. As blocks of EPS can be moved without heavy machinery and can be fitted together to form very large models, transportation of sculptures of any size is easily possible.
To provide the most to our customers, we keep distribution, installation, as well as tear down and removal if desired, all in-house. Our streamlined installation process is simple as we do it all ourselves. Local or international, we can offer delivery of your sculpture as well as the support of one of our knowledgeable teams to install it for your function.
Durable for Indoor and Outdoor Use
EPS foam is ideal for indoor and outdoor events. It does not put a weight strain on indoor floors, and outdoor weather has minimal effect.
- Durability – After the sculpture has been shaped, painted, and sealed with a protective coating of epoxy, it can sit on permanent display.
- Weather – EPS itself does not absorb water and when coated with a sealant, it won’t rot or mildew. The coating is highly resistant to mold and fungus.
- Finishes – Once our sculptures have been sealed and prepped for painting, they can be made to look like practically anything: wood, brick, stone, and so much more for your outdoor affairs.
While our sculptures can weather the outdoors without a second thought, they will need to be securely fastened because of their lightweight qualities. Wind is a natural antagonist to outdoor EPS installations. Also, sun damage is mitigated with the proper UV resistant coatings to keep your outdoor sculptures looking fresh for years.
Foam vs Other Materials for Sculpture
At Custom Engineered Arts, we are proficient in creating large sculptures from a multitude of materials. The two most commonly used materials for large scale sculptures are:
EPS Foam – The materials are inexpensive, lightweight, and can be produced quickly. With their protective coating for durability, they can last for decades.
|
Weight |
Production Method |
Production Speed |
Cost |
Detailing |
Best Use | |
|---|---|---|---|---|---|---|
|
EPS foam |
very lightweight |
Carving (subtract material) |
Fast |
very low |
good for rougher details |
Large sculptures |
|
3D Printing |
heavier (unless in a thin shell) |
Layering (add material) |
Slow |
high (machine and material) |
high to extreme |
Smaller, intricate sculptures |
3D Printing – 3D printing with ABS plastic allows for high detail levels and for internal supports in a hollow structure. In contrast, it has a slow production time and is more expensive.
EPS foam has the added advantage of zero-waste production. All sculptures begin as large foam blocks that are carved. However, all waste material is 100% recyclable and used in the next sculpture. Unless you are definitely sure that your sculpture is meant for a very long term installation, our recommendation is to use EPS foam for creation and installation of your large sculpture at your event or business.
Industries That Use Large Foam Sculptures
Large foam sculptures from Custom Engineered Arts are not just for trade shows. Many industries have sparked interest, drawn in customers, and made a splash with custom made EPS foam sculptures.
- Restaurants – oversized seats, themed decorations,
- Movie – large props, massive props for background sets
- Daycare – big cartoon mascots, themed decorations,
- Retail – themed and functional POS stations, grand logos and props
- Architects – architectural foam sculptures for aesthetic design
- And So Many More – corporations, education, museums, local municipalities, and so on.
The only limit to what we can fashion for your industry is decided by your imagination.
How Custom Foam Sculptures Are Made
Our custom foam fabrication process begins with design and 3D modelling to create a viable design. Engineers calculate structural needs, particularly for large structures, and computer-based fabrication machines precisely cut and shape EPS foam blocks. All removed material is completely recycled.
Manual foam carving for sculptures is done by artists to add intricate detail like textures and undercuts. Foam pieces are glued together and applied to a skeleton of wood and metal for large sculptures. The foam is made durable with a hardened protective layer that is finally painted with water-based paints to bring out a look of realism.
Conclusion
EPS foam remains at the forefront of large-scale sculpture fabrication due to its light weight, fast production, clear detailing, and low cost. It is moisture and mold resistant, has a high strength-to-weight ratio, and doesn’t shrink or expand. It can essentially be shaped into any form to make your message stand out.
