Foam PVC
About this foam pvc
Foam PVC is a closed-cell plastic sheet with a smooth matte face, so it prints far better than corflute and has no flutes showing through the image. It cuts cleanly to shape, holds a screw, and works indoors or out. Printed cardboard and honeycomb board sit alongside it for retail POS where the piece is light, short-lived and recyclable.
Materials compared
What each option is actually good for, so you can pick on the job rather than on the price alone.
| Material | Thickness | Indoor / outdoor | Expected outdoor life | Best for |
|---|---|---|---|---|
| Foam PVC | 3mm | Both | 3 to 5 years | Wall signs, shelf edge, small panels |
| Foam PVC | 5mm | Both | 3 to 5 years | Freestanding shapes and larger panels |
| Foam PVC | 10mm | Indoor | Not recommended outdoors | Dimensional lettering and thick edges |
| Printed cardboard | 2 to 4mm | Indoor | Not rated for outdoor | Short-run retail POS and shelf talkers |
| Honeycomb board | 10 and 16mm | Indoor | Not rated for outdoor | Large lightweight standees and headers |
Questions we get asked
Foam PVC or corflute?
Foam PVC where the print quality matters or the sign is seen close up: smooth face, no flutes, a proper edge. Corflute where it needs to be cheap, light and disposable. Foam PVC costs more and weighs more, and indoors it is worth the difference.
Does foam PVC warp?
It moves with temperature more than metal does, so a large panel fixed rigidly in direct sun can bow. Use slightly oversized fixing holes so the sheet can expand, mount it to a flat surface rather than spanning a gap, and step up to 5mm on anything large.
How do I mount it?
VHB double-sided tape on smooth, clean, painted wall for light panels, or countersunk screws with washers for anything larger. Foam PVC holds a screw but will crush if it is overtightened, so do the last turn up by hand.
Can it be cut to shape?
Yes, routed or knife-cut to any outline including internal cutouts. Supply a vector cut path with the artwork. Thicker sheet gives a more visible edge, which is exactly what you want for freestanding letters and dimensional pieces.
Is any of it recyclable?
Cardboard and honeycomb board are, and they are the right choice for a campaign with an end date. Foam PVC is a rigid plastic and is not accepted kerbside, so treat it as reusable and design it so the message can be re-covered later.