"Expanded Foam PVC - Yes It Is Real" Topic

I was watching a Youtube tutorial on road building, and thought perhaps the guy got the name wrong, since I'd never heard of this before, but turns out, it is indeed a real material.

He just called it E-PVC, or Expanded PVC, but here in the USA, it is listed as Expanded Foam PVC, at least by TAP Plastics.

Apparently, it is a lightweight version of PVC, with half the weight, and looks to be fairly rigid.

I don't know if it is a brand new product, or if it has been around for a while, but I've never heard of it before, and I frequent the plastics store occasionally.

It is used for retail signs apparently, since it is lightweight, rigid, and comes in several colors. Thicknesses are from 1/8" plus. One piece the guy was working on was 10mms thick.

$2.59 USD a square foot here, and $1.99 USD/sq. foot, if you buy a full or half sheet (4' x 4', or 4' x 8').

I may have to get a piece to try it out.

It appeared to be fairly rigid, like styrene, but can be cut with a razor knife, so perhaps a cross between styrene and extruded styrene foam. The latter is what I thought the guy was using, but just a different color (white).

Have any of you used it, or seen it in other stores, like home improvement stores in the USA?

Looks like it could be useful for various projects.

I haven't seen it in any local DYI stores but I have seen a few listings on ebay. I contacted a supplier and asked if they would send me a sample and they agreed if I paid for shipping ($1.50). I am looking forward to seeing what I can do with this.

Me as well.

It appears it can be cut, sanded, and filed, so seems very similar in composition to the extruded styrene foam.

I wonder if it is more rigid than that?

Look for a product called "Sintra" you may need to try builder's supply stores for it. They use it for backsplashes and bathroom, enclosures in commercial projects. The special effects and cosplay folks use it for lightweight armor costumes.

I have many sheets of sign material that matches your description. It's about 3/16" thick with a skin of sheet styrene on both siides. It is white, dimensionally stable (very stiff/doesn't warp), easy to cut with a matt knife, edges can be sanded and surfaces take paint very well. Super glue adheres the edges like "iron" and sheet styrene can be attached to the flat surfaces using styrene glue.

Think of it as awesome, waterproof, durable "foam core" type material with similar uses. Probably relatively cheap (mine were discarded signs). It might come in other thicknesses like Foamcore….but I don't know.

Suitable uses might be 28mm buildings, walls, "diy zone mortalis" layout or Deadzone/Necromunda type terrain features.

You might reach out to a sign company for scraps, or unprinted raw stock.

Thanks for the info, and the tip on sign companies.

Sounds perfect for some of the stuff I want to make.

Will have to hit up some of the sign shops locally.

Another trade name to look for is Palight. It does come in various thicknesses – I've got sheets of 1mm, 2mm and 3mm and have seen 5, 6 and 10mm being sold.

@ JSchutt – this is a different product to the one you described; more like styrene than styrofoam and not skinned like foamcore. Liquid polystyrene cement doesn't work on it though, so you'd need to use superglue or epoxy.

The advent of new materials and crafting tools have certainly made for exciting crafting times!

(As per Tamsin's post: what JSchutt is talking about is very probably a different material tot he one you are after)

"Foamed PVC" is its more common name… we've been selling it for about 5 or 6 years now…and it is awesome.

US manu: link

SINTRA™ is another American brand name.

It can indeed be cut, sanded, welded (CA), glued with tacky-glue, drilled, covered and sprayed on directly with aerosols.

It can also be thermoformed and comes in different colours and finishes (satin, matte, high-gloss).

3mm thick is more than enough for 28mm building walls, and 2mm will also do fine… 5mm is overkill.

Best way to cut it is to make a light initial cut with fresh sharp blade, and then follow that initial cut with repeated passes until material is cut through.

Do not try to cut all the way through in one cut.

Jed made an entire table from it a few years back… : link

hth

I went looking for EPVC and found very similar to what OP found. Different name in the states.

For a 4x8 sheet, I was quoted $50 USDUS. Budget being what it is, I'll have to wait for a bit to get that. Sign makers around me use up what they have and didn't have any scraps on hand (though I did get some nice thin styrene that works as plasticard!)

I'm looking for something that can be cut into curves (topo elevation lines). 3mm (1/8") thick. This won't work, I take it?

Any suggestions for something that's stiff, cuts reasonably easily with a smooth edge, an won't break apart like Styrofoam in a thin sheet?

@ emckinney – the ePVC is available in 3mm thickness and can be cut into curves with a smooth edge. Bevelling the edges is nice and easy too.

Excellent, thanks!

Now I just need to figure out where to get it locally …

Small amounts are on EBay as Palight for reasonable prices if you want to experiment. I ordered some to play with but it's not here yet. You can also order larger sheets – in many colors – thru Home Depot and then pick it up at your local store. None of my local stores has it in stock but check with your store(s) as some may have it in store. If this stuff is as good as it's reported to be I'm guessing that in time it will be readily available in DIY and art supply stores.

@ TamsinP,
Please tell us where & how you purchased 1 & 2mm sheets of the Palight you have. All I can find is the thicker 3mm sheets.
Thanks

@ Master Caster – I bought mine from 4D Modelshop: link

Antenocitis Workshop also sell it: link

Although I expect shipping from UK would rule them out for you. Your best bet would be to look for architectural model suppliers nearby.

@ TamsinP
Thanks. Sorry,,,should of looked to see where you lived. I will check out your suggestion as I'd really like some 1 & 2 mm thick. I'm impressed with the four 8"x8"X 3mm thick pieces I got on EBay. The pieces are perfectly flat and not cupped or distorted.