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Custom Foam Characters

Premium custom foam characters & cutouts for events/brands.
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What Are Custom Foam Characters?

Custom foam characters are your brand’s physical ambassadors, engineered from high-density foam blocks and transformed into vibrant, durable, three-dimensional figures. We use precision CNC carving and expert hand-sculpting to capture every detail of your design, then apply a rugged hard coat and automotive-grade paint for a flawless, long-lasting finish.

Unlike heavy, costly alternatives, they offer a lightweight, scalable, and highly detailed solution to bring your mascot or hero product to life for events, retail spaces, or permanent installations. They are strategic tools designed to stop traffic, create shareable moments, and build a real-world connection with your audience.

Royal Foam Art Design: Where Foam Board Cutouts Become Legends

We Build Everything In-House. Right Here in the USA

We sculpt, coat, and paint every character in our 45,000 sq. ft. US facility. This gives us total control over quality and ensures we meet your event deadlines without fail.

Decades of Character Creation

We have brought hundreds of characters to life for theme parks, major brands, and global events. Our work ranges from beloved mascots to detailed custom foam sculptures.

Limitless Customization

You conceptualise. We create it. Send your design here – from preliminary sketch to full 3D render – and we will produce an actual statue in any size or form.

Durable, Lightweight, and Safe

Our foam statues look like heavy stone or fiberglass but weigh close to zero. That keeps them light to move around, convenient for public display locations, and simple to install.

End-to-End Creative Partnership.

We’re your creative partner from start to finish. Our team works closely with you on every step of the way. We make sure we capture the perfect look and expression for your character.

Fast Quotes to Get You Started.

We offer you an exact and detailed quote in a period of hours. This enables you to obtain what you need to make headway on your project quickly and without hesitation.

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Putting an Idea into Reality.
With or Without a Finalized Design

We have a streamlined process. If you have already done character sheets or even have the germ of an idea, your personal manager will take you through it step by step.
Here’s how we make your vision a reality, step by step:
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How Royal Foam Art Design Engineers Personality

Creating a character is art. Replicating it perfectly at any scale is a science. We have mastered a process that fuses artistic talent with technology. This ensures every character we build is visually perfect, structurally sound, and built to last.
As a leading creator of custom foam sculptures in the US, we follow a rigorous process for every project.

Here’s a glimpse into our meticulous production process:

Production
stage

How it
works

What
influences it

Result

1. Concept & 3D Design
We create a digital sculpt from your art or brief.
Precise 3D renderings and technical drawings for your approval.
Client artwork, character personality, pose.
2. Material Preparation
We select and prepare high-density foam blocks.
A material base ready for sculpting.
Character size, structural needs, foam density.
3. Shaping & Detailing
Precision CNC carving creates the main form. Manual sculpting adds fine details.
A perfectly shaped, unpainted foam statue.
Machine precision, craftsman skill, design complexity, store lighting.
4. Coating & Finishing
We apply a durable hard coat, then airbrush and hand-paint to match the design.
A vibrant, durable, and perfectly colored character.
Coating formula, brand Pantone colors, desired finish.
5. Quality Control
We conduct a final inspection for color accuracy, structural integrity, and likeness.
A quality-assured character ready for display.
Inspection protocols, client requirements.
6. Packaging & Delivery
We design and build a custom crate for safe transport.
A perfectly protected character, ready for installation.
Packaging design, shipping logistics, campaign timeline.
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Production stage
1. Consultation & Material Selection
How it works

We analyze your part’s functional needs (stress, environment) to recommend the optimal engineering-grade material.

 

What influences it
A strategic production plan and optimized material selection engineered for performance and cost-effectiveness.
Result
Solid, lightweight base for fence components.
Production stage
2. Digital Prep & Slicing
How it works

Your CAD model is strategically oriented for maximum strength and then sliced into a flawless, machine-readable build file.

What influences it
A flawless, machine-readable build file that guarantees superior mechanical properties, dimensional accuracy, and an efficient print cycle.
Result
Part geometry, critical tolerance requirements, and the desired surface finish on key features.
Production stage
3. Industrial 3D Printing
How it works

In a precisely controlled chamber, our machines build your part layer by layer, fusing material with real-time monitoring.

What influences it
A raw, near-net-shape component, built with incredible layer-to-layer adhesion and structural integrity directly from your digital file.
Result
The chosen 3D printing technology (e.g., FDM, SLS) and the specific thermal and flow properties of the selected material.
Production stage
4. Post-Processing & Curing
How it works

Support structures are meticulously removed, and the part is cured via heat or UV light to lock in its final, peak material properties.

What influences it
A clean, dimensionally stable part, free of all temporary supports and fully cured to achieve its final, peak material properties.
Result
The intricacy of the part's geometry and the type of support material used (soluble vs. breakaway).
Production stage
4. Post-Processing & Curing
How it works

Our craftsmen handle any required finishing: precision sanding, painting to spec, media blasting, or installing hardware like threaded inserts.

What influences it
A production-quality 3d printing industrial part with the specified aesthetic and functional finish, ready for immediate integration into your final assembly.
Result
Your specific cosmetic requirements and any need for integrating non-printed hardware or secondary components.
Production stage
6. Final Inspection
How it works

Every part undergoes a rigorous final inspection with precision tools, verifying all critical dimensions against your original CAD data.

What influences it
A fully-vetted, dimensionally-accurate part that you can trust, with comprehensive quality documentation (like a Certificate of Conformity) provided upon request.
Result
Your specified tolerances and any requirements for advanced documentation like CMM reports or First Article Inspection (FAI).
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This rigorous process allows us to craft visual merchandising props that are a smart long-term investment.
We build the foam characters that become your most shareable brand experiences. Your character becomes a strategic asset, driving viral content, customer loyalty, and real-world sales.

Engage Your Audience Everywhere:
Lifesize Foam Figures for Any Venue

Your character needs a world to conquer. It becomes the focal point of a brand activation, the friendly face of a theme park, or the hero of an event. We understand the fast pace of retail. Your brand’s character is the perfect hero for your next campaign.
We build custom foam characters that become the centerpiece of your window displays and in-store promotions, helping you launch quickly, efficiently, and with flawless quality. Some of our most impactful character-driven display solutions include:
Kitchen Remodeling Example

3D Brand Mascots

Transform your company mascot from a logo into a tangible, lifesize foam figure. Perfect for corporate headquarters, trade show booths, and retail locations.

Kitchen Remodeling Example

Event Mascots & Photo Ops

Create a can’t-miss centerpiece for your festival, concert, or sporting event. Our large scale foam characters are designed to be magnets for photos and social media shares.

Kitchen Remodeling Example

Theme Park Props & Theming

We build durable, weather-resistant characters that can withstand the elements and the crowds, perfect for creating immersive and magical environments.

Kitchen Remodeling Example

Custom Foam Sculptures for Marketing

Launch your next campaign with a stunning foam statue that stops traffic and generates buzz. Ideal for experiential marketing, product launches, and pop-up events.

Kitchen Remodeling Example

Theatrical & Museum Props

From the stage to the exhibit hall, we create detailed foam statues and figures that bring stories to life with historical accuracy or fantastical flair.

Heavy Impact, Not Heavy Materials:
The Unmatched Benefits of Foam Sculptures

We create one-of-a-kind sculptures that build brand loyalty, cause excitement, and make your venue a destination. Branded merchandise allows agencies and brands to make a large splash in lean, effective ways.
What are benefits of our custom foam characters?

Create Unforgettable Photo Ops

Large-scale characters are powerful social media magnets. A custom foam sculpture transforms passive viewers into active brand advocates by providing a unique, sharable backdrop. Every posted photo acts as an organic endorsement, expanding your reach across digital platforms.

We engineer these installations for maximum impact, optimizing for lighting, camera angles, and group dynamics. From simple cutouts to massive 3D mascots, we create photogenic moments that make your audience look great and your brand unforgettable.

Amplify Your Brand’s Personality

A material's limits shouldn't compromise your vision. Heavy, expensive materials like wood or metal can be difficult to shape. They often need a lot of extra support. Foam fabrication removes those problems.

Whether it’s a goofy mascot for a consumer brand or a dignified figure for a corporate entity, we translate your brand attributes into a physical presence. This character becomes a silent spokesperson, communicating your values and story 24/7, whether it’s standing in your lobby, at a trade show or at a community event.
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Achieve Total Creative Freedom

Traditional materials like wood or metal have limitations. They're heavy, expensive to carve, and often need a lot of support. These issues can force you to compromise on your creative vision. Foam fabrication changes all that.
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We combine CNC precision with skilled hand-sculpting. This lets us create virtually any shape, texture, or size you can think of. We bring ambitious ideas to life, from delicate details to massive curves. Now your only limit is your imagination.

Enjoy Lightweight Portability & Safety

Transporting and installing heavy sculptures is complex. They need cranes, specialized crews, and structural assessments. Our foam statues make it simple. They're so light you can ship them across the country and a small team can handle them on-site. This reduces installation time and costs.

This lightweight nature also enhances safety. In public spaces like retail malls or event venues, heavy sculptures can pose a risk. Our foam characters, protected by a durable but resilient hard coat, are a much safer alternative, especially in areas with children. You get all the visual impact of a heavy monument without the associated risks and logistical headaches.
Our custom foam characters are an investment in your brand's story and personality. A unique character helps people connect on a deeper level, which drives results you can see. Your character becomes a memorable figure that builds loyalty, encourages repeat visits, and creates shareable content. This authentic engagement improves your bottom line.

Ready to Bring Your Character Off the Page and Into the World?

Let’s build something legendary together.

Get a free quote now

FAQ

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Foam characters

foam charactersIn architecture and design, there are moments when a seemingly small form or a tiny visual element ends up carrying an unexpectedly powerful impact. Sometimes a single detail can shape the entire character of a project – speaking louder than a full presentation or even an entire trade show booth. This happens especially in projects where the physical space itself becomes part of the message you want to communicate to visitors.

For example, when designing retail environments, creating branded installations, setting up corporate event zones, developing hospitality areas, building university campus spaces, or producing experiential activations, that one thoughtfully designed element can transform the whole narrative. Foam 3D characters are a perfect solution for exactly these kinds of tasks. They are lightweight, durable, easy to install, and incredibly flexible in terms of design. We can produce any style you envision – delivering a truly custom project that expresses the identity of your space and transforms a creative idea into a predictable, buildable, and visually striking result.

foam characters Over more than 20 years of work, we have produced both small foam board characters, foam board and large-scale foam character installations, and we’ve watched the industry evolve dramatically. Back in the early 2000s, clients mostly chose wooden or metal letters. But as architectural foam entered the market in the 2010s and foam-based architectural elements developed further, foam quickly gained trust. Clients started choosing it more and more because it is lightweight, strong, faster and easier to install, and capable of achieving an incredible range of visual effects — sometimes even effects that natural materials simply cannot reproduce.

Today, when we work with corporate clients, foam is chosen not only for its visual appeal but also for its advantages in timing, budgets, shipping efficiency, and installation cost. Foam checks all the boxes. That’s why architectural foam elements have become so popular and now hold a clear advantage over comparable architectural solutions made from traditional components.

What foam characters are and why professionals depend on them

Foam characters are custom-cut three-dimensional elements made from high-density architectural foam. They can be small decorative pieces, brand lettering, oversized mascots, architectural accents, stylized shapes, or full sculptural compositions. Everything is manufactured in the U.S.A. at our own facility, giving clients full control over lead times and quality.

Modern foam board characters stand out for several reasons:

Weight Reduction

extremely lightweight, reducing installation labor

Precision Matching

high dimensional accuracy that matches CAD drawings

Durability

long-lasting protective coating applied at the factory

Design Customization

full custom design flexibility – from wood grain to stone or metal finish

And most importantly, they arrive fully finished. No priming, sanding, or on-site painting.

A deeper look at how foam became a modern architectural material

When we entered the market 25 years ago, architects were cautious about foam. Most preferred wood, metal, or gypsum simply because they were familiar. But we watched a long-term shift happen: retail clients needed faster remodels, hotels wanted lightweight decorative pieces for large lobbies, and event companies desperately needed mobile, durable, oversized letters and mascots. Foam solved all of it.

Today foam board character cutout elements are standard practice in experiential branding and architectural décor. Modern foam components mimic wood, stone, concrete, and brushed metal so realistically that even contractors often can’t tell the difference until they touch it.

Materials and production technology

We work with high-density architectural foam engineered for durability and precision. It is:

Sustainability

environmentally responsible

Handling Ease

lightweight

Climate Stability

moisture- and temperature-resistant

Workability

ideal for carving, shaping, and painting

How foam characters are made: our production workflow

This is the part our clients are always curious about – and the part we’re most proud of. Over decades, we built a workflow that ensures reliability, accuracy, and flawless finishing.

Design development & 3D modeling

We analyze CAD drawings, images, brand guidelines, references, sketches – everything the client provides. It doesn’t matter whether the initial idea comes as a quick Pinterest screenshot or as a fully prepared technical drawing. We take that initial concept and develop it into a precise digital 3D model.

CNC cutting

We use industrial CNC machines to carve shapes from large foam blocks. This technology allows us to achieve incredible accuracy – down to a single millimeter. That’s exactly why clients trust us with foam characters for complex and highly detailed installations.

Hand refinement & finishing

Once the CNC stage is complete, our craftsmen step in. They adjust and refine the details by hand, making forms look more realistic, smoothing curves, perfecting transitions, and preparing each surface for coating. This step is essential – and it’s where the artistry happens.

Realistic textures

This is one of our strongest advantages. We produce custom pieces, which means all textures and colors are also custom. Everything is matched individually to your project, sealed properly, and finished so realistically that, when people see the pieces in person, they often cannot distinguish our foam from the real component we’re emulating.

Protective coating

Every piece gets a durable architectural coating. This step ensures longevity outdoors and indoors.

Color matching & painting

We paint all the pieces at the factory. Clients often bring us tile samples, facade components, or brandbook colors –  and we match them precisely.

Pre-assembly for easy installation

When size allows, we ship large pieces pre-assembled. That means fewer seams, fewer steps on site, and minimal installation time.

Every stage is controlled in-house at our U.S. facility – which is why our clients never worry about quality or consistency.

Shipping & logistics

Even oversized foam board characters ship easily thanks to reinforced packaging and rigid crates. We coordinate with trusted transportation partners to deliver nationwide – from Florida to Georgia, the Carolinas, Texas, and beyond. Clients especially appreciate predictability: deliveries arrive on time, in perfect condition.

Cost efficiency

custom foam sculpturesFoam dramatically reduces project costs in several key areas. Installation expenses drop significantly because foam elements don’t require any specialized heavy equipment or complex tools. That means you don’t have to spend money on renting additional machinery just to install the pieces. There’s also no need for lift equipment – the lightweight nature of foam allows installers to simply carry the components straight from the truck, often with just two or three people.

There are no extra painting or finishing costs either. Every piece arrives fully completed and installation-ready – all you need is adhesive and standard tools. Long-term maintenance expenses are also minimal, since foam is extremely easy to care for: a simple wipe-down is enough to keep it looking clean. It maintains its appearance regardless of weather conditions and typically lasts 10 to 20 years without any issues.

Traditional components we’re all familiar with may look impressive, but their heavy weight, complex installation requirements, and ongoing maintenance needs – especially with something like wood – significantly limit where and how they can be used. Foam characters, on the other hand, offer the same strong visual impact as natural or traditional components, but without any of the logistical challenges.

Where foam characters are used, with real-life examples

Retail & commercial spaces

Brands use foam board characters to shape memorable retail experiences.
For a Miami fashion retailer, we produced oversized concrete-texture letters for their seasonal launch zone. They looked like 400-lb blocks – but each weighed under 20 lbs and required only two installers.

Hospitality & entertainment

Resorts, hotels, themed spaces, and lobby areas often use foam elements to create a strong and memorable first impression. For example, a resort in Sarasota once invited us to fabricate a coastal-style seahorse sculpture for their property. We created a 7-foot-tall foam board character cutout, meticulously detailing every scale and finishing it with a beautiful metallic sheen. Guests couldn’t stop taking photos with it — the sculpture became a visual magnet. And even today, the hotel is strongly associated by its visitors with that very seahorse we created.

Architecture & real estate

We also produce architectural accents for facades, interior niches, decorative inserts, and statement elements for real estate projects. One of the more memorable projects was in Atlanta, where we developed geometric wall features for a modern residential building. The developer wanted something visually striking yet lightweight enough for installation on pre-finished panels. Foam handled this challenge flawlessly.

Marketing & events

Brands frequently come to us for foam pieces for corporate events, conferences, exhibitions, product launches, and even presentations of new restaurant menus. These elements help companies create a strong visual presence and elevate the impact of their marketing activities.

For a tech event in Orlando, we built giant logo letters – full foam board characters – in brand-specific PMS colors. They traveled across three states for a roadshow and still looked new.

Education & cultural spaces

Museums, galleries, student centers.
Once, we worked on a series of sculptural compositions for a museum in Savannah. We created complex, diverse shapes, layered surfaces, and integrated signage – all made from foam. Yet the final result looked like a genuine piece of contemporary art. Later, the curator told us that this particular corner had become the most photographed spot in the entire gallery. People simply couldn’t tell our pieces apart from real sculpture.

Sports & community events

Mascots, team logos, stage props.
A high school in Jacksonville commissioned a 10-foot mascot head for their stadium entrance. The original plan was fiberglass, but foam cut lead time in half and made installation possible without cranes.

Corporate interiors

Lobby statements, mission walls, 3D brand values, large logos
Tampa headquarters wanted a floating logo wall. Foam made it possible to install a massive sculptural logo onto glass partitions without stressing the structure.

Installation & maintenance

All of our pieces are delivered fully finished. They are primed, coated with a specialized protective layer, painted, and completely ready for installation. In addition, we provide full drawings and technical documentation. For more complex shapes, we also mark and label the elements so installers know exactly how to connect the parts and how to position them correctly. In most cases, installation requires nothing more than adhesive and basic tools.

Maintenance for our architectural forms is minimal. The protective coating preserves the appearance of each piece for up to 20 years.

Why working with Art Design is a long-term advantage

foam charactersWe combine:

  • 25 years of industry experience
  • U.S.-based production
  • custom design capabilities
  • 3D modeling
  • color matching to physical samples
  • 20-year warranty
  • predictable lead times
  • support from briefing to installation

Clients don’t just receive a product – they receive a complete, reliable solution.

Your next project can be faster, safer, and visually stronger

Foam is not a “cheap component.” It is a modern architectural tool that helps you:

  • meet your deadlines
  • reduce installation risks
  • expand your offering
  • increase margins
  • gain creative freedom
  • receive predictable results

If you want your next installation to look clean and polished, deliver a strong visual impact, meet all of your expectations for accuracy and detailing, and stay within optimal installation and delivery costs, just send us your idea, image or a request for a quote. We’ll prepare samples, 3D models, and everything you need to clearly understand how your project will look in real life.

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