Custom Rigid Signs - FAQ
Foam board handles short-term outdoor exposure of roughly 1 to 2 weeks for events, so a Saturday and Sunday market or open house works fine. Keep it out of standing water and direct rain. For anything longer, sintra under a covered area holds up better, and corrugated plastic Yard and Lawn Signs are the right call for fully exposed outdoor use.
Both have foam cores, but the face materials are different. Foam board uses smooth polystyrene faces, lightweight and affordable but prone to flex at large sizes. Gator board uses wood-fiber laminate faces, which are tougher, stiffer, and warp-resistant. At 24 x 36 in and larger, foam board sometimes bows away from the wall while gator board holds flat. The extra cost is worth it for lobby directories and gallery mounts.
Sintra is a brand name for expanded PVC sheet, a solid plastic material with no foam core running through it. That solid construction makes it denser than foam board and far less likely to absorb moisture at the edges. Choose sintra when your sign goes into a covered outdoor area, a humid loading dock, or any environment where foam board would soften and warp over time.
Foam board and gator board both go up to 4 ft x 8 ft. Styrene is typically used at smaller formats under 2 ft x 3 ft, because the thin 0.020 in sheet flexes noticeably at larger sizes. And sintra sizes vary by thickness. If you need a large sign that stays completely flat, gator board is the only substrate in this subcategory that holds without bowing at 24 x 36 in and beyond.
Yes. Every order gets a free digital proof showing the exact layout and colors before production starts. Production begins within 1 business day of your approval. If anything looks off, request a revision before approving.
