My day job has an event booth at a downtown convention center. They wanted some 3D signage on really short notice. I got the final artwork Saturday night so the only option for materials was what I could buy locally ...on a Sunday. I picked up about 25 sheets of foam board from Michaels, Joanns and Staples (getting the colors I wanted) and started the layout.
Three 7 foot signs and 2 smaller 28 x 18 ones. My old Profile doesn't have air assist so the boards had to be covered with application tape before lasering to protect from the smoke. Peeling the tape from all those letters took the most time.
They turned out nice and the client is quite pleased, but the signs are pretty fragile. When the board is cut, the foam layer resedes somewhat due to the heat leaving the edges and corners unsupported. These will be mounted up high away from traffic so it shouldn't be a problem.
This job took much longer than anticipated. There's no way I can charge for the actual time I have in on it.