Giant Foam Letters
Large-format letters for events, malls, photo opportunities, window displays, and branded environments.
CNC hot wire foam cutting in Knoxville, TN
Custom foam cutting for letters, logos, props, molds, packaging & retail displays.
865FabLab cuts EPS, XPS, PE, and selected EPP foam into clean, repeatable parts for events, signage, scenic builds, concrete molds, packaging inserts, and high-volume display programs.
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10hot wires for parallel production
4'×4'×8'foam bun cutting capacity
EPSletters, molds, logos, props
USAshipping or Powell pickup
Foam cutting services
Clean, scalable foam fabrication for business projects.
Our CNC hot wire foam cutting service is built for large-format shapes, repeat parts, and lightweight dimensional builds. The process creates smooth sealed edges with less dust than routing, making it ideal for EPS letters, logos, event props, retail display pieces, and mold work.
We work from CAD files, sketches, dimensions, or reference photos and can support one-off prototypes, short runs, and larger production batches.
Request a Foam Cutting QuoteCutting capabilities
High-output CNC foam cutting for oversized parts and repeat production.
Multi-wire hot wire cutting with up to 10 active wires
Up to two 4' × 4' × 8' foam buns processed at once
Contour, profile, bevel, arc, and radius cutting
Giant foam letters, logos, display structures, and props
EPS concrete molds and architectural formwork
Batch production for window displays and retail rollouts
Foams we cut
Material selection matters for safety and cut quality.
Good for hot wire cutting
- Expanded Polystyrene, EPS
- Extruded Polystyrene, XPS
- Polyethylene, PE / Ethafoam, with caution
- Expanded Polypropylene, EPP, case by case
Not suitable for hot wire cutting
- Polyurethane, PU, due to toxic fumes
- EVA foam, due to residue and poor cut quality
- Spray foam, due to inconsistent density and heating risk
Every customer-supplied foam is reviewed before cutting so the project stays safe, clean, and predictable.
Applications
Popular foam cutting projects.
Foam Sculptures & Props
Lightweight scenic forms for trade shows, themed spaces, marketing campaigns, and event builds.
3D Display Builds
Assembled foam structures, arches, igloos, backdrops, scenic displays, and specialty retail experiences.
Contour & Profile Cutting
Repeatable foam parts with bevels, arcs, radii, and nested layouts for production efficiency.
Moss Wall Structures
Lightweight foam bases for preserved moss, artificial greenery, scenic walls, and dimensional displays.
Retail Props & Branded Builds
Custom props, dimensional logos, themed product displays, and branded photo moments.
Finish options
Raw cut foam or display-ready parts.
- Hardcoating for improved durability and reuse
- Paint, graphics, and branding to match project requirements
- Multi-part assembly for oversized shapes and structures
- Rubber foam add-ons for packaging or cushioned support
- Hybrid builds using foam, Re-board, PET acoustic panels, lighting, or fabricated parts
Project workflow
How to start a foam cutting project.
1
Send details
Share CAD files, sketches, dimensions, quantity, deadline, and intended use.
2
Confirm foam
We review material, thickness, cut method, finish, and shipping constraints.
3
Quote production
You receive a practical fabrication plan with price, timeline, and next steps.
4
Cut and deliver
We fabricate, finish if needed, then prepare for Powell pickup or shipment.
Fast quote request
Send your foam project details.
Use this form for foam letters, EPS molds, packaging inserts, props, display builds, or production foam parts.
Ready to price your foam project?
Send your concept, CAD file, sketch, or part list.
We can help choose the right foam, cutting approach, finish, and delivery path.
Foam cutting FAQs
Common questions before requesting a quote.
Can you create giant foam letters and props?
Yes. We produce giant foam letters, foam logos, sculptural props, and lightweight dimensional builds for events, retail spaces, exhibitions, and branded displays.
What is the largest size you can cut?
We can cut up to two foam buns, 4' × 4' × 8', at the same time, which is useful for oversized parts and high-output batch runs.
What materials are compatible with hot wire cutting?
We cut EPS, XPS, PE, and selected EPP foams. We do not cut polyurethane, EVA, or spray foam due to safety and quality risks.
Can your system cut multiple pieces at once?
Yes. Our machine supports up to 10 hot wires running in parallel, allowing multiple identical parts to be produced in a single pass.
Do you offer foam molds for concrete?
Yes. We fabricate custom EPS molds for architectural casting, precast panels, and other concrete forming applications.
Do you offer shipping or pickup?
Yes. Orders can be picked up at our Powell, TN facility or shipped across the USA.