Signs & Large Format Print
Three technologies in one table
| Feature | Coated XPS foam | Routed PVC / Dibond / acrylic | 3D printed (channel letter) |
|---|---|---|---|
| From | approx. €13 / character | approx. €16 / character | approx. €44 / character (body) |
| Where | interiors, events, trade shows, stages | indoors and outdoors | indoors and outdoors |
| Thickness / depth | large, even a dozen cm or more, very light | usually the board thickness: 3–19 mm | any return depth, hollow body |
| Illumination | no | only as a background (e.g. halo on stand-offs) | yes: face, side, halo |
| Shapes | simple and rounded, no fine detail | any 2D outline, sharp edges | 2D outlines and 3D forms, rounds, chamfers |
| Finish | resin, RAL paint, vinyl | UV print, vinyl, lacquer | paint, acrylic face |
| Durability | moderate impact resistance, no water | good; PVC dislikes strong sun in dark colours | good, with a UV-resistant material |
Prices are for 30 cm letters. Each additional 10 cm of height adds approx. €11 net per character according to our price list: more material is used, and in illuminated letters more LEDs. For very large foam or PVC letters we price individually from the board nesting.
XPS foam: when it makes sense
We hot-wire cut XPS foam letters from a block, then coat them with resin and paint them in any RAL colour or cover them with vinyl. They are very light, so they can hang on double-sided tape or thin cords, or stand on a stage floor without any structure.
When we recommend them:
- large, thick lettering at a trade show, gala, wedding or in a recording studio,
- lettering on a reception wall, where depth and shadow matter,
- set design and decorations for one season.
When not: permanently outdoors, where someone might knock into them, and with fine, thin typefaces. A raw foam letter costs approx. €7 net (30 cm), but without a coating it dents and gets dirty easily, so the coated version, from approx. €13, is standard.
The surface also matters for fitting. On a smooth interior wall foam holds with double-sided tape and adhesive; on uneven render, plugs or a rail are better. On a stage or stand the letters often stand loose, sometimes with a small weight at the back so a draught does not topple them.
PVC, Dibond and acrylic: classic routed letters
This is the most common choice for a non-illuminated sign. We cut the letters on a CNC router from board, and the face stays in the material colour or gets UV print or vinyl. We fit them on stand-offs, plugs or tape.
- Foam PVC 10–19 mm: thick, light, inexpensive, good for interiors. It works outdoors, but dark PVC in full sun can deform, so on a south-facing facade we prefer another material.
- Dibond 3 mm: thin, rigid, weatherproof; often fitted standing off the wall, which gives a shadow effect.
- Acrylic 5–10 mm: an elegant, glossy look, coloured or clear with reverse print.
Non-illuminated Dibond or acrylic letters start at approx. €16 net per character at 30 cm high, stand-offs included. More on sign materials in acrylic, Dibond or PVC.
3D printing: channel letters without welding
A classic channel letter is made from a bent aluminium strip (the return) and an acrylic face. With simple typefaces that works very well. The problem starts with logos that have tight curves, small elements and rounded transitions: the profile has to be bent and joined by hand, and every joint is a potential leak.
That is why our farm of 7 3D printers includes machines dedicated to channel letters. We print the body in one piece, with no bending or welding of profile, with ready-made seats for the face and LED modules. This gives:
- accurate reproduction of a complex logo,
- any return depth and profile (straight, rounded, chamfered),
- repeatability for several identical signs for a chain of outlets.
A 3D-printed letter body 30 cm high costs from approx. €44 net per piece; finished face-lit letters from approx. €46, halo-lit from approx. €55 per character. Details on the LED 3D logos and emblems and illuminated letters pages. The differences between face, side and halo lighting are covered in illuminated 3D letters: types.
Example: a 9-letter name, 30 cm high
To show the scale of the differences, let us price the same lettering, e.g. a venue name of 9 characters:
- Coated XPS foam, indoors: 9 × approx. €13 = approx. €117 net
- Non-illuminated Dibond or acrylic letters: 9 × approx. €16 = approx. €144 net
- Face-lit letters: 9 × approx. €46 = approx. €414 net
- The same illuminated lettering, but 40 cm high: 9 × (€46 + €11) = approx. €513 net
Illuminated letters also need a power supply, cabling and installation, which we price for each specific sign. Our crews install (approx. €42 net per hour for a two-person crew plus travel at approx. €1/km), and the mains connection is made by the client's electrician or our qualified installer.
The most common mistake we see: someone chooses foam because it is the cheapest and hangs it over the entrance outdoors. After one season the sign has to be made again. Outdoors, go straight for PVC, Dibond or 3D-printed letters in a UV-resistant material.