1) THE DESIGN
With the Hot Wire Foam Factory it’s easy to make beautiful 3-D signs. Use a
computer, transfer type, or in-house artist, if you have one, to create your
lettering. Enlarge it to the desired size at your local copy shop. If it’s bigger
than 11”x17”, you might have to tile component pieces together. Pin the enlarged
copy onto a 1/2-2” thick piece of flat foam. Trace the edges of the letters
with a ball point pen leaving a visible indent of the letters on the foam. You
might want to darken the indents with a water-based felt pen before cutting.
2) CUTTING & TEXTURING
Use the Sculpting Tool, Hot Wire Scroll Table, or Hot Knife to cut out the letters
for your sign. Cut out the base-plate that you will be gluing your letters onto.
People have used anything from simple rectangles to ovals to animal shapes as
their base-plates. Use the Hot Wire Engraving Tool to enhance any details. Use
the Sculpting Tool to smooth out the edges and for any freehand sculpting needed
on your design. Use sandpaper for a finished look.
3) PAINTING & COATING
Use an outdoor latex paint and your sign should last for many years. If the
letters are a different color than the base-plate, paint them seperately, before
gluing on. Be sure to seal the back, too. If the sign will be hung where it
might be handled, use Hot Wire Foam Coat for a hardened finish. Test paints
and coatings on scraps of foam.
4) ASSEMBLY & MOUNTING
Lightly trace the sign pattern onto the base as a guide for gluing on the letters.
Use low temperature hot glue to adhere the letters. If it’s a small sign, try
mounting it with wall mounting tape. Pierce the base with the Engraving Tool
or Hot Knife for string or nails.
HOT
TIP: Multiple signs. Pin several pieces
of foam together before cutting to make extra sets of letters. Or cut the letters
out of a thick piece of foam, then slice them into multiple letters.
HOT TIP: Use letters that are connected to each other to save some time
gluing.
HOT TIP: Narrow straight letters are the hardest to cut out, thick and
curvy are easier.
HOT TIP: Wood grain look. Stroke the foam longways with a wire brush.
HOT TIP: Recycle. Check your local shops, especially appliance stores,
for free scraps of polystyrene packaging foam.