Back
Large-Scale EPS Dimensional Letters with Hard Coat — UNF Installation System
Project Type: Large 3D Dimensional Letters
Location: Jacksonville, FL
Client: FASTSIGNS (Reseller)
Industry: Commercial / Institutional Signage
Product: Custom EPS Foam Letters with Hard Coat
Materials: EPS Foam Core with Polyurea Hard Coat
Timeline: 14 Business Days
Result: Delivered oversized freestanding dimensional letters with integrated mounting solution, ready for direct installation onto a concrete foundation.
PROJECT OVERVIEW
A sign company required large-scale dimensional letters for an outdoor installation.
Key requirements:
- Clean, bold typography at large scale
- Durable exterior finish
- Structural mounting solution integrated into letters
- Ready for installation on a concrete base
This was not just lettering — it was a complete installation-ready assembly.
THE CHALLENGE
Design Requirements
From client proof:
- Letter height: 48”
- Depth: 4”
- Total length: approx. 108”
- Mounted on a continuous base platform
Key Constraints
- Letters must remain lightweight despite size
- Must withstand outdoor conditions
- Installation needed to be simple and reliable
- Precise alignment across multiple large characters
Technical Risks
- Warping or deformation at large scale
- Weak mounting points inside letters
- Paint inconsistency across surfaces
- Difficulty aligning letters on-site
THE SOLUTION
Integrated Letter + Mounting Design
Instead of producing loose letters, the solution included:
- Letters mounted on a shared base platform
- Pre-engineered structure for alignment
- Installation-ready configuration
This significantly reduced installation complexity.
Structural Reinforcement
Critical feature from invoice:
- Two internal PVC sleeves (3” diameter x 40” height)
- Positioned inside letters for post mounting
- One located in the “U” and one in the “F”
This allowed:
- Secure anchoring into concrete
- Stability against wind and movement
- Hidden structural support
Material & Finish
- EPS foam core for lightweight construction
- Polyurea hard coat for durability
- Sanded surface for smooth finish
- Exterior-grade paint application
Color Accuracy
Specified colors:
- Pantone 289C (primary letter color)
- Cool Gray 6 (base platform)
Client provided sample for precise color matching.
FABRICATION PROCESS
Step 1 — Design & Layout
- Converted proof into production model
- Calculated spacing and proportions
Step 2 — Letter Production
- Foam shaping for each character
- Assembly onto base structure
Step 3 — Structural Integration
- Installation of internal PVC sleeves
- Reinforcement for mounting points
Step 4 — Hard Coat Application
- Polyurea coating applied
- Surface prepared for finishing
Step 5 — Finishing
- Sanding for smooth texture
- Multi-stage paint application
- Color matching to client specification
INSTALLATION APPROACH
The system was designed for direct post mounting into concrete:
- Sleeves allow insertion of structural posts
- Platform ensures alignment between letters
- Simplifies on-site installation
RESULTS
- Delivered within 14 business days
- Clean, high-contrast finish
- Accurate color matching
- Stable mounting solution integrated into letters
VALUE FOR SIGN COMPANIES
Faster Installation
- Pre-aligned letters reduce labor time
- Built-in mounting eliminates guesswork
Structural Reliability
- Internal reinforcement improves longevity
- Suitable for permanent outdoor installation
Visual Impact
- Large scale creates strong presence
- Clean finish enhances brand visibility
WHEN THIS APPROACH MAKES SENSE
- Campus signage
- Corporate branding installations
- Entry monuments with lettering
- Freestanding identity signs
WHY THIS PROJECT STANDS OUT
Most dimensional letter projects focus only on appearance.
This one combines:
- Visual scale
- Structural engineering
- Installation efficiency
It’s a complete solution, not just lettering.
PERFORMANCE
- Lightweight compared to solid materials
- Durable hard-coated surface
- Weather-resistant finish
- Stable anchoring capability
CLIENT IMPACT
The reseller received:
- A ready-to-install product
- Reduced installation time
- Reliable structural performance
- Consistent, high-quality finish
FAQ
Q: Can large letters be installed directly on concrete?
Yes, using internal sleeves and posts as shown in this project.
Q: Are these letters strong enough for outdoor use?
Yes, polyurea hard coat provides durability and protection.
Q: Can colors be matched exactly?
Yes, Pantone matching or physical samples can be used.
Q: Do letters need additional framing?
No, structural support is integrated into the design.
Read more
Two Matching Apartment Monument Signs with Integrated Address and Accessibility Identification
3D Sign Factory produced two matching custom monument signs for Paradise Gardens Apartments, combining dimensional property…
Custom Illuminated Monument Sign For Brock Health
3D Sign Factory produced a custom architectural monument sign for Brock Health, combining a large circular…
Brookhaven – A Double-Sided Monument Sign Design with Integrated Address Identification
The finished structure follows the approved 3D concept closely while giving the property name and address…
BARRY ARMSTRONG – From 3D Concept to Two Matching Fabricated Monument Signs
The monument signage design was built around a strong central identifier: a large horizontal oval carrying…
Sugar Bear Antiques Mall Custom HDU Sign
Sugar Bear Antiques Mall called for something very different from a conventional commercial sign. The business…
Floating Letters Monument Sign for Chateau Allison
3D Sign Factory partnered with a regional sign company to fabricate a striking set of oversized…
Custom 3D Foam Characters for Immersive Displays
3D Sign Factory manufactured a collection of custom 3D foam characters, including an ant, a spider,…
3D Printed Piggy Bank and Camera Props for Creative Juice Trade Show Booth
Designed as photo-worthy attractions within a vibrant event booth, the props transformed digital brand elements into…
Case Study Industrial 3D Printing
Industrial 3D printing has revolutionized the way companies develop prototypes, manufacture custom parts, and streamline product…
Custom 3D Mascots That Turn Brands into Experiences
When companies want to create memorable brand interactions, few marketing elements are as powerful as a…
Recommended Articles
HDU Signs: What High-Density Urethane Foam Is and Why It’s a Premium Sign Choice
HDU is a rigid, closed-cell foam sold as boards and blocks in a range of densities, usually measured in pounds per cubic foot. Sign makers commonly work with 15 to 30 lb.
Acrylic Signs for Business: Types, Benefits, and How to Choose the Right Style
Most quality differences start with how the sheet was made. Cast acrylic is poured into molds and cured, which gives a bright polished edge, even color, and better long-term UV resistance.
Industrial 3D Printing: Large-Scale Foam Prototypes, Models & Manufacturing Solutions
At 3D Sign Factory, we combine advanced CNC machining, digital fabrication, and industrial foam manufacturing to create large-scale 3D printed-style products that are lightweight, durable, and cost-effective.
Molds for Stone Signs: The Foundation Behind Consistent Architectural Signage
At 3D Sign Factory, custom molds are engineered using advanced CNC technology, high-density foam fabrication, and precision manufacturing techniques that allow architectural stone signage
Beyond the Booth: How Custom 3D Displays Make Brands Stand Out at Expos and Events
From oversized logos and dimensional lettering to sculptures, props, and fully customized brand installations, three-dimensional fabrication gives companies
