Project Description
From Idea to Impact in 6 Simple Steps
See how we turn your concept into a show-stopping 3D reality.
Your Project’s Journey
with Royal Foam Art Design
Step 1
Discovery & Planning
We start by understanding your goals, timeline, and budget. Whether you have a detailed CAD file or a simple sketch, we define the path to success together.
STEP 2
3D Modeling & Prototyping
Our designers convert your assets into production-ready 3D models. We provide high-precision renderings for your review, ensuring every angle and proportion aligns with your vision.
STEP 3
Detailed Quote & Agreement
You receive a transparent proposal detailing the scope, materials, timeline, and payment options. We finalize the plan and approve the maquette before production begins.
STEP 4
CNC Cutting, Coating & Finishing
We bring your project to life. Your design is carved from high-grade EPS or HDU foam, hard-coated with durable polyurea, and finished with expert painting and texturing.
STEP 5
Secure Crating & Logistics
Packaging, logistics, installation or handover to the client
STEP 6
Ongoing Partnership
We ensure your satisfaction with our warranty, support for reorders, and advice on maintenance to maximize the lifespan of your investment.
From Our Workshop to Your World
Ready to Start?
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Here’s What We Need:
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Personal manager
Free visualization
Accurate execution
of the task
Compressed deadlines (from 3 days)
Safe delivery
Warranty and support
24/7 project support
FAQ
What are visual merchandising props?
Turnaround times vary based on project complexity and scale, but most projects are completed within 15-30 days from design approval. We also offer rush services for clients with urgent deadlines—just let us know your event date.
What kind of files or drawings do you need to start a project?
We can work with almost anything you have. For precise quotes and fabrication, vector files (.AI, .EPS) or 3D models (.STP, .OBJ) are ideal. However, we can also develop a full 3D design for you from a concept sketch, a photograph, or even just a conversation.
Are your foam products durable enough for permanent outdoor use?
Absolutely. We specialize in fabricating for outdoor environments. Our EPS foam products are sprayed with a signature polyurea hard coat, which creates a seamless, waterproof, and impact-resistant shell that protects against harsh weather, UV radiation, and physical contact.
How does the process work, from the initial idea to delivery?
Our process is designed to be simple and collaborative. It starts with a consultation to discuss your goals, followed by a detailed quote and 3D design rendering for your approval. Once confirmed, we move to fabrication, finishing, and finally, secure shipment directly to your site.
Can you match our exact brand colors?
Yes. We can precisely match any Pantone, Sherwin-Williams, or Benjamin Moore color code to ensure perfect brand consistency across all your marketing materials and installations.
We plan to reuse our props for a multi-city tour. How should we care for them?
Our props are built for durability and reuse. We recommend storing them in their original custom crates in a cool, dry place. The hard-coat surface is easy to clean with a simple soap and water solution, ensuring your props look pristine at every stop.
How are large foam structures shipped and delivered?
Every piece is meticulously packaged in a custom-built crate designed specifically for its shape and size to ensure maximum protection. We coordinate nationwide freight shipping to deliver your project safely to your business, event venue, or installation site.
How do you get a quote for a custom project?
Simply use the “Get a Quote” button on our website or contact our team directly. To provide the most accurate estimate, please include the project dimensions, any design files you have, your desired finish, and your project deadline.
What is the difference between EPS and HDU foam?
In short, EPS (Expanded Polystyrene) is extremely lightweight and cost-effective, making it perfect for large-scale sculptures, letters, and event props. HDU (High-Density Urethane) is denser and has a smoother finish, making it the ideal choice for detailed routed signs and projects requiring a premium, carved appearance. We will recommend the best material for your specific needs.
Your products are lightweight. How are they installed securely?
The lightweight nature is a key advantage for installation. Depending on the application, we use a variety of proven methods, including industrial-grade adhesives, hidden mechanical fasteners, integrated mounting brackets, or internal ballast systems to ensure every installation is secure and stable.
We only have a concept. Can you help us develop the design?
Absolutely. We function as a design partner for many of our clients. Our team can take your initial concept, mood board, or sketch and develop it into a production-ready 3D model, providing expert guidance on materials and finishes along the way.
What is the expected lifespan of your outdoor monument signs?
When properly fabricated with our polyurea hard coat and finished with UV-stable paints, our outdoor monument signs are engineered to last for 20 years or more with minimal maintenance, resisting cracking, fading, and water damage.
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