Laser cutting foam letters is a great application for your Epilog Laser machine. The laser easily cuts through the foam material, allowing you to create dimensional pieces for signage projects, photo props, and much more! Add some personalized messaging to your next event or celebration with this fun idea!

Download Graphics

Materials Needed

  • Polyethylene foam - we selected the quarter sheet size, which is 54" (1371.6mm) by 24" (609.6mm), and 1" (25.4 mm) thick. Depending on your table size, you may need to manually cut the foam with a utility knife to fit within the laser, or request a custom size foam sheet.
  • Spray paint (optional).
  • Utility knife (optional.)
  • Epilog Laser System

We used a Fusion Pro 48 120w:

Engraving: Speed: 24% // Power: 100% // Frequency: 100

Step 1: Setup

Open the artwork files and customize as necessary. If you opt for a different font, make sure it is thick enough to hold when moving and mounting/placing the letters. Thinner fonts can be more delicate, a thicker one will ensure less breakage.

graphics for laser cutting foam letters

Step 2: Send the Job to the Laser

After you've modified the artwork to your liking, insert your foam piece into the laser and send the job over with the correct parameters for your machine. After you've focused, manually move the table up by .15". This helps ensure the beam goes entirely through the foam. The foam isn't very dense, so you likely will not need an abundant amount of power to cut through it, and you can always run it again if the laser doesn't go completely through the first time.

laser cutting dimensional foam letters

Step 3: Spray (paint) and display!

After your letters have been cut, apply a few coats of spray paint. After the paint has dried you are good to go!

Spray paint your letters or phrases to make them fit your decor.
The completed laser cut foam letters.

Where can you sell laser engraved foam letters?

  • For point of purchase displays
  • Event signage
  • As photobooth props

Get Free Brochure & Samples

Receive brochures and samples, and get more info from us or your local distributor.


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