Foam boards—known as foam core, PVC foam sheets, or by brand names like Sintra or Forex—are versatile materials used everywhere from art classrooms to construction sites. Their lightweight yet rigid structure makes them ideal for signage, insulation, model-making, and displays. But one crucial factor often puzzles users: sizing. Let’s break down the dimensions you’ll encounter globally.
Standard Sheet Sizes: The Industry Workhorses
Most manufacturers adhere to a few common sizes, balancing practicality with shipping efficiency:
- 4×8 ft (1220×2440 mm): The most widely available size globally, used in construction, signage, and furniture. Examples include PVC foam boards from brands like TOME and GoldenSign.
- 5×10 ft (1525×3050 mm): A "big size" option for large displays or architectural applications, often listed as a premium choice.
- 60×90 cm (600×900 mm): Smaller panels like Tokushu Foamboard cater to crafts, school projects, or retail displays.
Large-Format & Custom Sizes
For industrial or specialized needs:
- Oversized Panels: Up to 2050×3050 mm (≈6.7×10 ft) for seamless exhibition backdrops or CNC machining.
- Custom Cutting: Many suppliers (e.g., Zhongniu, Alands) offer tailored dimensions for unique projects.
- Insulation Boards: Owens Corning’s FOAMULAR® CodeBord comes in 48×120 inch (1219×3048 mm) sheets with shiplap edges for construction.
Thickness Variations: Matching Function to Form
Thickness dictates rigidity and application:
| Thickness Range | Common Uses | Examples |
| 1–6 mm | Lightweight signage, photo mounting | 3mm Sintra for indoor displays |
| 9–18 mm | Furniture, 3D signage, models | 16mm laminated PVC for 3D logos |
| 20–60 mm | Structural insulation, marine cores | FOAMSTEP panels with PET/PVC foam |
Note: Density (0.3–1.8 g/cm³) also affects strength—e.g., high-density Celuka boards (0.65–1.8 g/cm³) for durability.
Specialty and Niche Sizing
- Toolbox Inserts: Precision-cut polyethylene sheets like 1/4" x 48" x 108" (6.35×1220×2743 mm) for organizing tools.
- Skirting/Trims: Decorative XPE foam borders (e.g., 230×8 cm) for home decor.
- Low-Loss Foam: RF-friendly sheets in 60"×48" (1524×1219 mm) sizes for electronics.
How to Choose the Right Size
Consider:
1. Project Scale: Small prototypes? Opt for 60×90 cm panels. Billboards? Use 5×10 ft sheets.
2. Material Efficiency: Larger sheets minimize waste but require storage space.
3. Thickness Needs: Thin boards (3–6 mm) bend easily for curves; thicker ones (18mm+) support weight.
4. Supplier Flexibility: Alibaba vendors often cut to size, while retailers like Wahchit Stationery sell fixed dimensions.
Outline: Key Takeaways
1. Introduction
- Foam boards’ versatility and sizing importance.
2. Standard Sizes
- 4×8 ft (1220×2440 mm), 5×10 ft (1525×3050 mm), 60×90 cm.
3. Large-Format & Custom Options
- Up to 2050×3050 mm; supplier cutting services.
4. Thickness Guide
- Ranges from 1mm (flexible) to 60mm (structural).
5. Specialty Dimensions
- Toolbox inserts, trims, RF foam.
6. Selection Tips
- Match size to project goals and material properties.
Whether you’re framing a photo or insulating a skyscraper, foam board dimensions shape your project’s feasibility and finish. Always verify tolerances with suppliers—especially for custom orders—and consider thickness-density interplay for optimal performance.
