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Die cut foam boards start with the same high quality foam board stock used across our lineup. Each board is cut to your exact shape using a digital flatbed cutter, then printed in full color, so what you receive is a finished display piece ready to use.
Also referred to as custom shape foam board or foam board cutouts, this process allows you to create signage that follows the exact outline of your design.
This is the right product when a standard rectangle is not enough. A logo shape for a trade show booth. A life size character cutout for a retail floor. A branded silhouette for an event backdrop. Die cut foam boards are more noticeable than standard rectangular signs because the shape itself draws attention before any text is read.
We print in full color UV ink directly onto the board surface. Colors are rich, accurate, and fade resistant with proper care. Every board arrives finished and ready to display.
Need a standard rectangular foam board? We also offer standard foam board printing in sizes from 11" x 17" up to 36" x 48" with single or double sided printing. See Foam Board Printing →
Features
Size
Perfect for smaller walls, desks, and close-range viewing. A great choice for office signage, reception areas, or home décor where space is limited but you still want impact.
Our most common choice for foam board printing. Balanced size that works well for offices, retail displays, and general signage.
A reliable everyday size for signage and wall displays. Great for logos, branding, and general use across most environments.
Classic poster dimensions that people are familiar with. Ideal for presentations, marketing displays, and larger wall areas.
Designed for more visibility. Works well when your sign needs to be seen from a distance without going oversized.
Maximum visibility and impact. Best for trade shows, feature walls, and high-traffic areas.
Shapes
What Shapes Can Be Cut
Any shape can be cut. Our digital flatbed cutter follows your vector shape file and cuts the foam board to your exact specifications. There is no die tooling required and no minimum order for custom shapes.
Logo and Brand Shapes
Cut your foam board to the exact outline of your logo, wordmark, or brand mark. Clean edges and sharp corners are achieved with our digital flatbed cutter.
Geometric Shapes
Circles, ovals, arches, hexagons, stars, arrows, and other geometric forms. Common for retail displays and event signage.
Character and Person Cutouts
Life size cutouts of people, mascots, or characters. One of the most requested uses for die cut foam boards.
Silhouettes and Freeform Shapes
Animals, objects, vehicles, food shapes, and product outlines. If it can be created as a vector path, it can be cut.
Custom Text Shapes
Boards cut in the shape of letters or words. Used for event signage, photo setups, and branded displays.
Die Cut vs Standard
Not sure which option fits your needs? Use this guide to choose between standard rectangular boards and fully custom die cut shapes.
Standard Option
Standard Foam Board
Rectangular boards in sizes from 11" x 17" to 36" x 48". Single or double sided printing. Same day available on select sizes.
See Standard Foam Boards →Current Page
Die Cut Foam Board
Cut to any custom shape. Logos, silhouettes, character cutouts, and more. Sizes up to 48" x 96". 2 business day turnaround.
✓ You are hereFile Setup
Die cut foam board orders require two separate files — your print artwork and your shape file. Setting these up correctly ensures accurate cutting and clean final results.
File format: PDF, AI, or EPS preferred
File format: Vector only — AI, EPS, or PDF with live paths
A vector file is made from paths instead of pixels, allowing it to scale to any size without losing quality. Common formats include AI, EPS, and vector-based PDFs.
If your file is not vector, we can help convert it.
Bleed (0.125") extends beyond the cut edge to prevent white edges
Both should be set up before submitting your file.
If you’re unsure about your files, contact us before ordering and we’ll review them. Design assistance is also available if needed.
Board Specs
3/16" works for most applications. Step up to a thicker option if your board will be handled frequently, transported between events, or needs extra structural rigidity at a large size.
FAQs
A die cut foam board is printed in full color and cut to a custom shape using a digital flatbed cutter. Unlike standard foam boards, which are rectangular, die cut boards can be produced in any shape including logos, silhouettes, and character cutouts.
Any shape can be cut. Common requests include logo outlines, circles, ovals, stars, arrows, character cutouts, custom text, and freeform shapes. Your shape file must be in vector format.
Shape files must be in vector format such as AI, EPS, or PDF with live vector paths. JPG or PNG files cannot be used for cutting. Submit your shape file separately from your print artwork.
Standard foam boards are rectangular and can be printed on both sides. Die cut foam boards are cut to a custom shape and are printed on the front side only.
Standard sizes include 18" x 24", 24" x 36", 30" x 42", 36" x 48", and 48" x 96". You can also enter a custom size directly in the cart for instant pricing.
Double sided printing is possible, but it is not recommended for most die cut foam boards. The cut edges expose the foam core, which can affect the appearance when viewed from the side. For best results, die cut foam boards are typically printed on the front side only.
3/16" is the standard thickness available in the cart. Thicker options such as 1/4", 3/8", and 1/2" are available through custom quote.
White is the standard option available in the cart. Black foam board is available through custom quote.
No. Die cut foam boards are intended for indoor use only. The surface can absorb moisture and may warp if exposed to rain or humidity. For outdoor use, PVC boards are recommended.
Most die cut foam board orders are produced within 2 business days. Rush options may be available depending on the project.
Yes. Life size cutouts are one of the most common uses. Submit your artwork along with a vector outline and we will cut and print it to your exact shape.
Artwork should be set to a minimum of 150 DPI at final print size in CMYK color mode. Include a 0.125" bleed and keep important elements at least 0.25" inside the cut edge.
A vector file is made from paths instead of pixels, allowing it to scale without losing quality. It is required so the cutter can follow the exact shape of your design.
Yes. Enter your exact dimensions in the cart for instant pricing. For larger or unique sizes, you can request a custom quote.
Foam boards can be mounted using command strips, foam tape, or push pins. For freestanding displays, use an easel or sign holder.
Yes, with proper handling. Store them flat and keep them away from moisture. Thicker boards are better for repeated use.
Orders can range from a single board to large quantities. Higher quantities may require additional production time.
Yes. We can assist with artwork setup or converting files into the correct format for cutting.
Foam board is lightweight and cost effective. Gator board is more rigid and durable, making it better for displays that will be reused or handled frequently.
Yes. Installation services are available for larger or more complex projects.
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