Bespoke Cast Resin Letters

Bespoke cast resin letters. Over the years we have been making cast resin letters for our customers, we have a range of moulds that we use to cast from in standard sizes. Resin letters are the choice when the customer wants 3D letters to put on their building and they want them to last for decades.

Over the last couple of years we have been developing a way of making one use moulds. This allows us to produce bespoke cast resin letters. These letters can be made to any font, colour, size and thickness. The problem that we have not been able to get past is that they take too long to make commercially, so sadly we do not advertise it on our website very much. The letters do tend to weigh rather a lot as they use a lot of resin when they are 50mm thick.

Bespoke resin letters only come in a matt finish at the moment. Back to the drawing board.

Now, it’s funny how, when looking for one solution you come across another by mistake. The resin that we found to make the bespoke cast letters is solvent free, no more fumes, great. The resin does not attack polystyrene, so we are now able to make 3D sculptures without the fumes. Getting polyester resin to go with polystyrene was a bit of a task. Problem solved, don’t use it, use this other resin instead.

To be honest I think in most circumstances powder coated stainless steel letters does the job just as well. We make stainless steel letters and they will last a life time.

So, if you do want 3D letters think of stainless steel built up letters, they are easier to make and last just as long as solid cast resin letters.

How to make 3D Polystyrene Letters

How to make polystyrene letters for the home or for hobby crafts.

The usual way to make polystyrene letters would be with a hot wire cutter. This is the way that we make them when we are making letters for our customers. If you want to make letters for domestic use for the home for putting onto the wall and painting them there is a way to make them without a proper hit wire cutter. You can use a scroll saw to make the letters instead. You can also use a jig saw with a (101a blade).

First make a paper templates of the letters required which you can make by printing them off from a computer. Tape the paper templates onto 1mm thick card. Cut the card with a craft knife, next use drawing pins to fix the card template onto the polystyrene. Use a scroll saw to cut the polystyrene letters, the card template will help you to get a better shape for the letters.

Once the letters are cut you can smooth the letters off with a medium grade sand paper. Paint the letters with a vinyl matt emulsion. Gloss paint will usually melt the letters. The letters can be finished off with a gloss finish but only if you cover the letters with a couple of layers of epoxy resin or exterior grade PVA.

To buy your polystyrene try contacting your local builders merchant or DIY store. They often keep sheets in thicknesses of 25mm and 50mm in stick.

When cutting the letters with a scroll saw please remember to use a face mask to stop you from breathing in any dust.

When cutting the card template  you will find it easier to cut the straight lines first and then do the curves, use a ruler as a guide, if you try to cut a straight line with out a ruler you will end up with a wobbly line. Practise your cutting before you try to make the letters.

www.polystyreneletters.co.uk