Materials / Foam Board
We make custom foam board 3D puzzles of your building, product, vehicle or logo, die-cut and printed in full color. Light, detailed and cost efficient in large quantities, they make a corporate gift or trade show giveaway people actually carry home.
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Classic New York landmark
Metrohm lab, a client anniversary gift
Football stadium
School campus with bus
Summer camp grounds
Airport with control tower
FDNY fire engine
Backhoe loader in company colors
CSKA Sofia stadium and team bus
SUV with dealership logo
Davie icebreaker ship
Blue sports car
Service van with your logo
Box truck for a trucking company
Turboprop aircraft with display stand
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Watch video 12Detailed buildings at scale. Foam board holds fine print and complex shapes, so it is our first choice for detailed architectural models, from headquarters to stadiums and campuses.
Lowest cost in large runs. Once the die-cut molds are made, production is fast and the price per piece drops as the quantity goes up. It suits orders of 1,000 units and more, which is our minimum for foam board.
Light enough to take home. A foam board puzzle weighs very little and fits in a briefcase or carry-on, so trade show and conference guests take it with them.
Foam board works for almost any shape. Sheets can be cut, half cut, scored and slotted to build layered walls, curves and even domes.
Popular foam board puzzles include buildings, stadiums and campuses, interiors and lab spaces, full dioramas with figures, trucks, ships and aircraft and product replicas. Projects like our Metrohm lab and Hexagon metrology lab were made in foam board.
Full color printing. Every piece is UV printed on a smooth paper liner, so logos, small text and building textures stay sharp. A gloss coating or lamination protects the surface.
Extras. We can add small figures, vehicles, signs and LED lighting, like the school puzzle with its lit windows and school bus.
Packaging. Foam board puzzles ship flat in a custom printed box, mailer or poly sleeve, with your branding and building instructions.
Warm and tactile, laser cut from plywood or MDF. Ideal for small models, keepsakes and premium corporate gifts.
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Eco-friendly and versatile. Perfect for creative designs, educational puzzles, or DIY coloring experiences.
Read MoreFoam board is built for big runs. Once the die-cut molds are made, every puzzle in your order comes out identical, and the price per piece gets better the more you order.
Minimum order: 1,000 units. Foam board is made with die-cut molds, so the price per piece keeps dropping as the quantity goes up.
Timeline: about 3 months from concept to delivery. With air shipping, it can be done in as little as 2 months.
How it works: send us a photo, drawing or logo and get a free concept visual in as little as one business day. Once you order, we build the 3D model and send you a physical sample to approve before production. See the full process.
Price: every quote is all-inclusive. Design, sample, production, DDP shipping, customs and taxes are included, delivered to your door.
Not sure if your idea works in foam board? Send us a photo and we'll tell you, along with a free concept visual.
Foam board is light, detailed and affordable in large quantities, which makes it a natural fit for events and company-wide gifts where every guest, employee or student gets their own model:
Trade shows and conferences: a light foam board model of your building or product is a giveaway guests can carry all day.
Openings and anniversaries: give every guest the new building or campus as a keepsake.
Client and employee gifts: a detailed model of your headquarters or lab that stays on the desk.
Schools and fundraisers: a puzzle of the school building for every student or donor.
Foam board, also called foam core, is a rigid polystyrene core between two paper liners. The core keeps each piece flat and stable, and the paper gives a smooth surface for printing.
The pieces are die-cut with steel molds. This gives clean edges and tight fitting slots that are the same on every puzzle in the run, whether you order 1,000 or 10,000.
The finished model is light but sturdy and looks sharp on a desk or shelf. It is not meant for heavy handling like a toy, but it holds its shape for years as a display piece.
What is a foam board puzzle?
It is a 3D puzzle made from printed foam board sheets. The pieces press out of the sheet and slot together into a freestanding model, with no glue.
What is the minimum order for foam board 3D puzzles?
The minimum is 1,000 units. Because foam board is made with die-cut molds, larger orders get a lower price per piece.
How long does it take?
About 3 months from concept to delivery: design and sample take 2 to 4 weeks, production 2 to 4 weeks, and shipping 2 to 4 weeks. With air shipping, it can be done in as little as 2 months.
How much do custom foam board puzzles cost?
The price depends on the size, the number of pieces, extras like figures or LED lights, and the quantity. Send us your idea and quantity and we will send an all-inclusive quote.
Is foam board the same as foam core?
Yes. Foam board and foam core are two names for the same material: a foam center with paper on both sides.
Should we choose foam board or wood?
Foam board is best for large, detailed buildings and big quantities. Wood suits smaller, premium pieces where the feel of the material matters more than fine print detail.
Tell us what you'd like to create and how many you need. We'll get back to you with a free concept
visual and quote in as little as one business day.
