UNIQUE POLYSTYRENE

Polystyrene was discovered in 1839 by a German apothecary, but only started being commercially manufactured in 1931 by the I.G Farben company as a possible replacement for die-cast zinc.

Polystyrene is a plastic material that has unusual properties due to its structure. It is made by combining ethanol and benzene with various technologies and is composed of individual cells of low density polystyrene, which makes it extraordinarily light, reasonably strong and an excellent insulator.

This durable material is as strong as unalloyed aluminium but much more flexible, and so is ideal for low-cost signage, or even temporary signage. It can be bonded using special adhesives and coated with epoxy and various other non-flammable paints and substances in the manufacturing of signs.

SHAPE TO FIT

Polystyrene can be cast in finely detailed molds and comes in various thicknesses and sheet sizes. Flat-cut letters, polystyrene logos, 3D models and displays can all be constructed out of polystyrene.

It is most easily cut with a hot-wire foam cutter, which is made with a heated length of wire that vaporises the foam as it cuts. Polystyrene cut and shaped in this way is often used in the signage industry. Alternative cutting methods include using regular blades, which must be dipped in water and used at an angle, or 3 and 5-axis routers, for large-scale prototyping.

Polystyrene can also be glued or nailed, and thinner sheets are ideal for die-cutting and thermo-forming. Polystyrene is not particularly weather resistant and so should not be used outdoors for extended periods of time, unless it is coated. Coating polystyrene protects the closed cell plastic substrate and makes it denser than PVC, so that it does not become brittle or crack.

This lightweight plastic is particularly user-friendly and has very little effect on the ozone layer, although it does have to pass various other quality control tests and standards.

POLYSTYRENE MEETS DIGITAL

Digital printed cast vinyl films with company logos can be mounted on to both sides of a polystyrene sign and attached by magnetic tape, foam tape or liquid nails. These mounted graphics are very popular on walls and ideal for designers making use of large spaces.

Professional sign-designers use this substrate in conjunction with Perspex faces and digital printing for signs that carry powerful communication messages, logos and branding concepts.