Category: Brands

Giant Form Props for Tradeshows

We produce a lot of giant foam props for tradeshows, casinos, theme parks and many other industries.

Foam props are designed to be lightweight, portable and strong. Supporting someones weight is an important aspect, along with determining how they’ll be using the prop.

There are a lot of initial questions that go into determining what type of prop you may need. The more the needs can be defined the better overall prop.

Here are a few questions we ask clients:

  • Will they be sitting on it for long periods of time?
  • Standing next to it?
  • Touching the top of it?
  • Walking around it or flat against a wall?
  • What areas will need to be protected more than others (less of a hardcoat means you save more $$)

Whether it be large 26 ft tall Poseidon statues or 5 ft tall gummi bears, what we can produce is only limited by your imagination.


We’re able to work within confined areas and maximize the usage of space. 

Benefit of Using Foam in Theming

What are the benefits of using foam?
Foam is one of those amazing materials that provide a variety of benefits for theming projects. Foam is light weight, easy to sculpt and extremely versatile. 

Light Weight
EPS Foam (expanded polystyrene) comes in a few different densities. You can think of densities as being how many small foam beads are packed into a square inch. The more beads that are packed together, the greater the overall weight but the more detail that can be captured. We typically use 1 lb EPS for the majority of most props.

Easy to Sculpt
Foam itself is extremely easy to sculpt. Using basic tools such as sanding pads, a hot knife or a rasping pad, you can remove a lot of material quickly. 

Foam can be used for wall panels, large props, ceiling elements, practically anything you can think of. Once hardcoated, the foam is encapsulated allowing it to be protected from fires, wind, rain and practically anything else mother nature can throw at it.

Organic vs Complex sculpting…the approach makes the difference.

When it comes to sculpting, there are really two paths to take, either organic or complex, with each method having its own set of pros/cons including precision, pricing, delivery and more.

Sculpting Organic Shapes
Organic shapes can be anything from an orange to a tree to a myan temple…basically anything that is irregular or asymmetrical. If you look at anything in nature, you’ll find organic shapes. These can often be easier to sculpt by hand as they don’t need to be exactly precise which can save time by not having to program a a CNC machine. 

Sculpting Complex Shapes
This method involves precision. When the design must be exact with no room for interpretation, a different kind of approach is needed. This usually entails a CNC machine of some sort that offers precise movements producing an exact representation. Usually these are objects that need to appear perfect and symmetrical in appearance. CNC Machines can vary between flat bed tables with a vertical spindle (basically the drill bit) or a multi-axis machine that is capable of going up, down, side ways, upside down…you get the idea. 

When looking at pricing you have to take a look at the entire picture. With organic sculpting, you’re looking at primarily two costs…labor and materials. Because a human would be sculpting this no 3D model or toolpathing processes are required. The hands are the robot so to speak! With CNC machines, you’re looking at various costs including toolpathing, 3D modeling and then the time to run on the robot. If you want exact precision though, the robot is the only choice.


Sculpting materials that are low in density (i.e. 1 lb EPS foam) can be performed by a sculptor. However, if you take 2.5 lb density foam (roughly 2X the density and weight as 1 lb foam) the ability to sculpt by hand goes away and the requirement to use a robot is required.