When you're looking to create an outdoor sign, one of the most important decisions you'll make is the substrate. The substrate is the material that your sign will be made of, and it will affect everything from the sign's durability to its appearance.
In this blog post, we'll take a look at four of the most common substrates for outdoor signs: foam, metal, wood, and plastic. We'll discuss the pros and cons of each material so you can choose the best substrate for your needs.
Foam
Foam board is generally delicate and not very sturdy, making it best suited for indoor use, framing, POP displays (pop-up displays), exhibits, and kiosks. However, some foam boards are tougher and come with wood fiber layers for increased resistance against dents and scratches, although still recommended for indoor use.
Most foam boards can be customized via printing, cutting, routing, and painting. There are variations of foam board that are moisture-resistant and have smooth textures instead of rough textures.
High-Density Urethane Board (HDU) is a subtype that's perfect for outdoor signs and displays. HDU foam board is specifically designed for creating three-dimensional signs and displays, as well as for hand-carving.
This type of board can be painted with almost any type of paint after properly priming it. Its fine, grain-free surface reduces the need for sanding, which saves time during the priming, painting, and finishing process. Additionally, HDU is moisture-resistant and durable, which means it won't crack, rot, or peel, guaranteeing longevity for the signage.
The suitability of foam substrate for indoor or outdoor use depends on its specific properties. Generally, foam substrates are water-resistant and mold-resistant. With a variety of options for painting and printing, foam substrates can be a viable solution for signage needs.
Foam Products we offer:
Foam Board (Gatorfoam, UltraBoard, Fome-Cor)
Metal
Aluminum is the most commonly used metal substrate for signs, with three primary types: Alumalite, Aluminum and Steel Composites, and Plain Aluminum. These substrates are strong, lightweight, and great for outdoor use.
- Alumalite is a durable metal substrate with a baked enamel finish offered in colors like blue and red. This double-sided material can last up to ten years and will not swell, corrode, rot, or delaminate, making it a solid choice for long-lasting signs. Alumalite can be used in a variety of sign types, including wall/fence-mounted signs, billboards, post & panel signs, backlit signs, cut-outs, channel letters, scoreboards, POP (pop-up) displays, Kiosks, and more. It accepts screen printing, digital flatbed printing, and vinyl lettering, offering great flexibility in customization options.
- Aluminum and Steel Composites offer a range of finishes, including glossy, matte, and flat, and are easy to cut and route. They can be customized with vinyl, digitally printed vinyl, or most paints, providing flexibility for creative design. This lightweight and rigid substrate has a flat, smooth surface that comes in various colors and finishes to accommodate your creative needs. While durable for outdoor use, it is also suitable for indoor use. Overall, this substrate allows for creative freedom and versatility in design.
Metal substrates are traditionally favored for outdoor use due to their strength and durability, though they are also commonly used indoors. With its versatility in color, shape, and printing options, this rigid material offers endless possibilities for designing your sign and adding that extra touch of creativity.
Metal Sheets we offer:
Aluminum and Steel Composite Sheets (ACM Panel, ALPHA Panel, DiBond)
Wood
Wood substrates offer a handmade, organic feel that other substrates lack. Available in plain or primed styles and in both simple planks and complex composites, it adds warmth to any sign. Suitable for both indoor and outdoor use, it requires extra care and maintenance, including finishes, protective coatings, and sealed edges to prevent warping and deterioration over time. Some types are treated to resist moisture, rot, and termites. With good weather resistance and minimal cracking and warping, wood substrates are durable, requiring infrequent upkeep. This versatile substrate can be sandblasted, routed, laser engraved, painted, or carved to achieve your desired design.
Wood Substrates we offer:
Wood Composites (Extira, Lusterboard, MDO, OMEGA, PSP, Scooter Board)
Plastic
Plastic substrates offer exceptional flexibility to meet your specific needs. Types include acrylic, corrugated plastic, polycarbonate, PVC, Styrene, and Flexface, each with varying levels of durability. All of these materials are strong enough to be used in indoor and outdoor displays, with the exception of Styrene which is recommended for indoor use only.
- When working with Acrylic substrates, screen printing is the recommended and only option for use with certain paints and inks. Acrylic has a consistent thickness, tolerance, and color that allows for easy creation. It can also be laser cut, saw-cut, drilled, cemented, thermoformed, and fabricated due to its excellent weatherability, light transmission, and overall versatility.
- Corrugated plastic substrates are durable and able to withstand high impact, making them suitable for both indoor and outdoor use. It offers multiple customization options such as hand painting, screen printing, or vinyl lettering.
- Polycarbonate substrate sheets are both UV-resistant and solar grade, ensuring durability and protection from the elements. Its high impact strength and pleasing aesthetics make it an exceptional choice for outdoor signage. Additionally, polycarbonate can easily accept vinyl lettering with appropriate techniques and is available for purchase by the foot off the reel.
- PVC is an extremely versatile plastic substrate that can be easily manipulated through a variety of techniques such as saw cutting, routing, knife cutting, die punching, and heat forming. It can also accept different kinds of paints, screen prints, digital prints, and vinyl films. PVC frequently comes in a smooth, low-gloss finish and can be obtained in a range of colors to suit your needs.
- Styrene is primarily utilized for UV printing and thermoforming, and is generally only recommended for indoor applications. It boasts high-impact strength and is typically finished with a matte surface.
- Flexface is a versatile plastic substrate that can accommodate a range of printing methods including UV, vinyl, solvent, eco-solvent, and latex inks. It possesses anti-fungal and anti-wicking properties and is frequently utilized for backlit signs, awnings, and banners. Notably, it is both tear and curl-resistant and can be radio frequency welded. As its name implies, Flexface is admired for its flexibility.
The longevity of plastic substrates is determined by their specific type, and the choices of printing and painting techniques may be restricted based on the desired design. Therefore, if a particular plastic substrate is not compatible with your creative sign design needs, seeking an alternative option may prove beneficial. However, it's critical to be mindful of the recommended indoor and outdoor usage requirements.
Plastic Substrates we offer:
Acrylic (Acrylite, ALPHA, Chemcast, Plaskolite)
PVC Sheets (EX-Cel, Free Foam, Komatex, Sintra, Sintra-Vers)
Knowing facts like which substrates are naturally water resistant, and which need extra coating can make your substrate choices not only easier but smarter. When you build your sign or set up your next display, you know what to do! The knowledge of what can and can’t be printed on what substrates and their uses can mean the difference between fulfilling your creative ideas and settling for less.
We carry a wide selection of substrates and accessories, and you can check them out here.
