How to Make Large Styrofoam Letters

Styrofoam is always handy in many aspects; the core benefit of Styrofoam is the lightweight feature. You can use it in many ways, specifically for design purposes. It is easy to cut them, and you can also shape them as you want. Today we are going to discuss an easy technique on how to make large letters using Styrofoam. We will be discussing all the necessary apropos to the procedure. All the steps included in this procedure are stated below chronologically.


For this process, you will need some necessary things. These elements will help you accomplish the procedure correctly. You will need Styrofoam, and the size of the Styrofoam should be large enough to accommodate the letters. Then you will need a Cricut machine for making the templates of letters. But if you do not have a Cricut machine, you can use a regular printing machine for this purpose. You will need a poster board for attaching the letters.

Then you will need paper and cardboard. You can also use some laces and ribbons to embellish the edges of the letters. It would be best if you used a hot knife machine for cutting the Styrofoam, but you can also use a standard cutter. And lastly, you will need some glue and spray paint to decorate the letters. After you have gathered all these elements, you can start the main work.

You have to write the letters according to the dimension and then print them out using a Cricut machine or a printer. You have to use a poster board and use a cutter, and you have to take out the letters. The letters’ size should match; for this reason, you have to use a stipulated measurement. Then you have to take the letter and then attach them to the Styrofoam board.

Now you have to use a hot knife to carve the letter out of Styrofoam. You can also use a regular knife for this reason. Afterward, you have to take the Styrofoam letters and paint them using spray paint. You can also use laces to seal the edges. Now you have to seal the porous outlook of the Styrofoam. For this, you have to print another set of letters, which will be precisely similar to the Styrofoam letters, and then you have to carve them out using a cutter.

Now you have to use glue to attach them to the top of the letters. For applying glue on the cardboard, you have to wait at least thirty seconds after applying the glue, or else the cardboard becomes sticky. After you have used the cardboard on the top of the letters, you should start pressing them. It will help the letters merge with the Styrofoam. In this way, you can make large Styrofoam letters easily.


Lastly, we hope that the process we have discussed here will help make large letter s out of Styrofoam. For the best result, you should follow the steps chronologically, and you can also add other colors and decorative aspects to your latter. It will be beneficial if you use a frame to attach these letters. Thank you for your time. Have a nice day.

You may read also our other article :

  1. How to Router Letters into Wood
  2. How to Make Cardboard Letters Stand Up
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