Fabrication Workflow
From file to finished piece.
Every project is engineered and quoted to order. Whether we are milling a hardwood lobby sign or assembling a 12-foot architectural pediment, your build follows the same five-stage shop workflow.
- 01
Concept, CAD & Engineering Review
Send us your vector logo, 3D model, elevation drawing, or reference sketch along with target dimensions and where the piece will live.
Accepted formats include .DXF, .AI, .SVG, .PDF, .STEP, .STL, .OBJ, or annotated reference photos. We verify wall thickness, internal armature needs, and seam locations before cutting.
- 02
Material Spec & Fixed Quote
We recommend the right substrate and protective finish for your environment and budget, then provide a clear custom quote.
Whether a piece needs high-impact polyurea for a trade show floor, cementitious coating for an exterior façade, or UV-stabilized resin on white oak, everything is specified upfront.
- 03
Multi-Axis CNC Fabrication
Your piece is precision-milled from high-density EPS foam, kiln-dried hardwood, or architectural composite directly from the digital toolpath.
Large-scale builds are milled in interlocking sections, bonded, and fitted with internal steel or timber armatures when rigging or freestanding ballast is required.
- 04
Hard-Coating, Resin Inlay & Scenic Finish
Foam builds receive a structural polyurea or stone-texture shell followed by automotive or scenic paint; wood signs receive deep-pour or flush epoxy inlays.
Every surface is sanded, sealed, and finished for its real-world setting—from aged metallic film patinas and gloss trade-show colors to satin catalyzed wood finishes.
- 05
Quality Inspection, Crating & Delivery
We photograph the completed build for sign-off, then prepare it for workshop pickup, GTA/Ontario delivery, or crated freight shipping.
Mounting hardware, French cleats, standoff kits, or installation lift points are included as specified in your project scope.
What to send when requesting a quote
- Artwork or Reference: Vector logos (`.SVG`, `.AI`, `.PDF`, `.DXF`), 3D models (`.STEP`, `.STL`, `.OBJ`), architectural elevations, or a rough hand sketch / inspiration photo.
- Approximate Dimensions: Overall height, width, and depth (or the wall/booth space it needs to fill).
- Environment & Handling: Indoor lobby, high-traffic trade show floor, film set rigging, or permanent outdoor exposure.
- Target Deadline: Let us know if your build is tied to a shoot date, product launch, or construction schedule.
Scheduling & lead times
- Production lead times typically range from 1–3 weeks for custom signage and 2–5 weeks for large-scale coated props or architectural runs.
- Digital proofs and scale check-ins are shared prior to final finishing.
- Rush fabrication for film shoots, product launches, and trade show deadlines is available depending on shop capacity.
Frequently Asked Questions
Technical & logistics answers
How durable is a CNC foam prop or architectural element?
Raw EPS foam is lightweight, but once sprayed with our structural polyurea elastomer or architectural cementitious shell, the surface becomes impact-resistant, dent-resistant, and weatherproof—strong enough for high-traffic trade shows, film sets, and building exteriors.
What file formats do I need to start a quote?
You don't need production-ready CAD to get a quote. A rough sketch, reference photo, brand logo (.SVG, .AI, .PDF, .PNG), or approximate dimensions are enough for pricing. If you already have 3D files (.STEP, .STL, .OBJ) or architectural elevations (.DXF, .DWG), you can attach them directly.
How large can you build?
Because large foam sculptures and architectural mouldings are CNC-milled in precision-indexed sections and chemically bonded before hard-coating, there is virtually no upper size limit. We build everything from 24-inch lobby signs to 15-foot trade show props and full building façade accents.
Can epoxy signs and foam props be used outdoors?
Yes—when specified for exterior use. For outdoor foam installations (such as columns, pediments, and monument displays), we seal the core in polyurea or fiber-reinforced architectural coating with UV-stable exterior coatings. For outdoor wood & epoxy signage, we pair exterior-grade hardwoods with UV-inhibited resins and marine-grade topcoats.
How are oversized pieces shipped and installed?
Lightweight foam construction keeps freight costs dramatically lower than cast stone, fiberglass, or solid timber. We offer direct delivery across Barrie and the Greater Toronto Area, as well as custom-crated LTL freight shipping across Canada and the US.
Ready to start Stage 01?
Upload your reference files and dimensions for a custom engineering review and quote.