How to make this sign?

[Viktor Voroncov]

There is few designs of OUTDOOR signs. One sample is attached. The problem is that we need relatively large number of this signs (and of course at low possible price
Ideas -
3D routing from something like SignFoam - expensive, long time

Hot wiring from PPU foam - not possible make some designs, signs are too light, porous, need much more work for finishing

Injection of PPU foam into form? Not sure that this is possible at all.

Ideal looks injection of foamed PVC into form and we are ready invest some amount of $ in equipment and materilas but expect total of investment inside $10 000. Possible? Description of technology? Technology of finishing?

We are open for cooperation with somebody who already have this/similar technology in USA as we have a lot of customers here in Europe.

ANY ADVIСES/SUGGESTIONS ARE WELCOMED!!

[james mcgrew]

either thermopress or a mold, both need one cnc mold and plug.

jim

[Viktor Voroncov]

Thermopress - which materials use for filling inside? How better connect two parts of sign? Which material use for thermopressing mentioned fact that painting will apply after?

Molding - looks like size will be too big for molding. Diameter is 28", 36"

[james mcgrew]

you can make two sides "snap" together or meld them with heat, fill interior with eps foam, and decal or raise the lettering in the mold


if you have a lot of them contact a shop which does this they will know

[Viktor Voroncov]

Thank's James, will work in this direction.

[james mcgrew]

it is a pretty cool process, we made surrounds for out door monitors this way

http://www.productiveplastics.com/va...vePlastics.com

[james mcgrew]

http://vacuum-forming.com/