Over the years we have spent a lot of time making 3D letters in stainless steel, moulded acrylic, styrofoam. MDF and now cast resin.
The cast resin letters that we make are manufactured in two different ways. One way is to use a silicon mould and fill with a polyester resin. The second method we use a one use mould and fill it with a resin then we break the mould to release the letter.
The second method is not cost-effective and takes too long to make. Still, we have enjoyed messing about with projects so we still produce these for the challenge.