PROPS · SETS · DECORATION

Props, figures and scenery from Styrofoam

Cut, mill and robustly coat large shapes – from the single piece to a complete theme world.

Large figure from Styrofoam for props sets and decoration

FROM IDEA TO OBJECT

Whatever you can imagine can be built

At the start there is often just a drawing, a 3D model or an idea: a giant figure, a fantasy world, a rock, an animal, a lettering or a complete set.

Styrofoam makes large shapes light. From an unremarkable block, volumes, contours and whole bodies are created in a short time. The hot wire first removes the material that is not needed. Where the geometry becomes more complex, the CNC milling machine then takes over and works out details, curves and three-dimensional surfaces.

But it is the surface that turns the lightweight core into a finished object. With Qspray or Speedliner the part gets a robust protective layer – ready for paint, use and the next story.

So from a Styrofoam block, step by step, something emerges that previously existed only in your head: cut, mill, coat – done.

EXAMPLES

What can be made from it?

From the single figure to a complete theme world: the following examples show which products can be made from Styrofoam.

Figures & sculptures

People, animals, fantasy figures and free sculptures – from the rough volume to the finished surface.

Scenery and stage sets from EPS for film, TV and theatre

Film, TV & theatre

Scenery, stage sets and large set pieces for theatre, film, television and TV productions.

Rocks & landscapes

Rock formations, caves, landscape elements and organic structures for indoor and outdoor staging.

Theme worlds and theme-park decoration from Styrofoam

Theme parks & theme worlds

Theme objects, facades and complete experience areas for theme parks, attractions and fantasy worlds.

Trade fair, event and retail objects from EPS

Trade fair, event & retail

Large eye-catchers, spatial objects as well as shop and window-display decoration for trade fair stands, events and retail.

Product replicas & brand objects

Oversized products, packaging and brand objects that impressively enlarge real originals.

Columns and architectural decoration from Styrofoam

Architecture & columns

Columns, capitals, ornaments and large-format architectural elements for sets and decoration.

Outdoor furniture from Styrofoam with robust coating

Outdoor furniture & design objects

Seating objects, benches, lounge furniture and free design and furniture geometries with a lightweight core and a robust coating.

MACHINES

The shape is created in two steps

Not every prop has to be fully milled. Large volumes can be prepared quickly with hot wire; complex surfaces and details are then created on the CNC milling machine.

CUT3000S series – cut large shapes quickly from the block

The CUT3000S series is the fast route from the EPS block to the blank. Large contours, tapered or independent 4-axis geometries and free basic shapes are cut with hot wire directly from the block.

Especially with large props, only the material actually needed for the 3D geometry then has to be milled. This reduces milling volume and makes the combination of hot wire and milling machine particularly attractive.

With optional rotary tables and a lathe function (turning), rotationally symmetrical parts such as columns, bodies and recurring decorative elements can be produced.

The cutting contours come as a DXF or DWG drawing; styroCAM Draht generates the IsoGcode for the hot wire from it.

View CUT3000S series

CUT3000S CNC hot wire machine for props and large EPS shapes

W4 series – when the blank becomes a real 3D shape

Where hot wire reaches its geometric limits, the work of the W4 series begins. The 4-axis CNC milling machine processes complex three-dimensional geometries, curves, transitions and details.

This is how faces, figures, rocks, organic shapes and freely modelled surfaces can be created from a pre-cut EPS blank. Hot wire handles the volume – the W4 series the details.

For 3D machining, the 3D model is loaded into a CAM software that generates the Gcode, or machine program, from it. The milling machine then produces directly from these paths.

View W4 series

W4 series 4-axis CNC milling machine for props and 3D shapes

COATING

Light at the core. Strong at the surface.

The EPS core gives the object its shape. The coating determines how robust the finished surface becomes.

Qspray – spray a hard coating directly onto the part

Qspray 1000 S is a polyurea cartridge spray system for coating EPS parts. The hard protective layer turns the lightweight core into a considerably more durable object.

This is particularly suitable for props, decorations and custom parts where the shape should stay light but the surface has to withstand more in daily use.

View Qspray

Speedliner – when the prop really has to take a beating

Speedliner Pro is a sprayable protective coating for robust surfaces. It can be tinted in RAL colors and thus combines surface protection and color in one further production step.

Especially for outdoor objects, event elements and heavily used decorations, the lightweight EPS core becomes a finished part with a resistant surface.

View Speedliner

Speedliner protective coating for robust props and outdoor decoration

PROPS FROM EPS

Frequently asked questions

Which material is used for props?

Props, sets and decorations are made from EPS (Styrofoam). The material is light, can be cut and milled into large shapes quickly and is then robustly coated.

How is a large prop made?

First the shape is created in two machining steps: the hot wire quickly cuts the rough volume from the EPS block, then the CNC milling machine (W4 series) works out the three-dimensional details, curves and surfaces. The part is then coated.

How robust does the surface become?

Through the coating: Qspray applies a hard polyurea protective layer, Speedliner a robust protective coating that can be tinted in RAL colors – depending on load and use.

Show more questions

Why hot wire first and then milling?

The hot wire removes large volumes very quickly. That way the milling machine only has to process the material actually needed for the 3D geometry – which saves milling time.

How large can the objects be?

Almost any size. The size of a single part is limited by the machine’s working area, but larger objects are built in segments: the prop is split into several parts, cut and milled individually and then assembled into the complete object. This is how oversized figures, sets and complete theme worlds are created.

Are the objects suitable for outdoor use?

Yes. With a robust coating such as Speedliner, Styrofoam objects become resistant enough for outdoor decoration, events and heavily used applications.

What do you need from me for a project?

A 3D model, a drawing, a photo or an idea is enough. Together we define what is pre-cut with hot wire, what is milled and how the object is coated.

How does my 3D model get onto the machine?

For the hot wire, styroCAM Draht generates the IsoGcode from DXF or DWG data; for the milling machine the 3D model is loaded into a CAM software that generates the Gcode, or machine program. The machine then produces directly from this data.

YOUR PROJECT

Bring us the idea – we will find the production route

Advice on props sets and decoration from EPS

With props it is rarely the part that is the problem – but the question of how to produce it economically.

Send us your 3D model, a drawing, a photo or just an idea. Together we check which areas are pre-cut with hot wire, which are milled and how the finished object can be coated.

On request we test the process with your project directly on our machines.

Discuss the project