News

Reverse-cut letters and logos are custom made for single-use concrete casting. Once the concrete is sufficiently hardened after casting, foam letters must be dissolved out to reveal the cast letter shapes. Use a natural citrus solvent (or benzene, which has health risks associated with exposure and contact) to remove the foam from the concrete. Other letter forms, like mdf or reverse-cast metals must be attached to the form for casting and heavily lubricated to be extractible. Request a price quote for your project here.   There are several kinds of letters and casting forms available.  For the largest of projects, there are custom created forms for use in a very large concrete cast. The largest of the forms may have CAD-cut or router cut letters and logos included with a relief background as pictured in these examples. Foam letters can also be custom cut in small sizes and large, display sizes for events and exhibitions or dramatic lobby entrances and display windows. For casting smaller projects, you can now choose from these options:Economy foam, 1" thick,6" to 24" tall*. view hereSmooth foam, 1/2" and 1" thickness,4" to 24" tall. view hereNew tapered form letters in routed and shaped mdf**, 0.25", 0.5" and 0.75" thick,3" to 24" tall. coming soonForm letters in cut mdf**, 0.125",  0.25", 0.5" and 0.75" thick,3" to 24" tall. coming soonReverse-cast metal letters (for multiple uses), around 0.75" thickin sizes 6" to 18". view here*Available with a paper installation template at extra cost.**MDF is a medium-density fiberboard material. Request a price quote for your project here. Several articles of interest: Very large letters in foam,Concrete letter casting basics, Casting letters for concrete pavers and walls, Installing foam letters, Cheap sign option using foam letters, Concrete casting basics 101 and our Business wall letter selection guide. Request a price quote for your project here.

This is a beginner's guide to the basics of casting concrete For specific details, search online for how to create concrete casting forms.To cast concrete with lettering and a logo if desired, you need a form, concrete and letters.The form can be on a flat surface, into which you can pour your concrete, or the form can be erect with a bottom, sides, a front and a back. Be sure to mix sufficient smooth concrete so that a spill or leak won't scuttle your casting pour. Stir and poke the concrete to reduce incidence of air pockets.For the sake of simplicity, this article focuses on using a flat form or pan for making pavers.After deciding on the form or pan shape and size, follow the basic preparation instructions. Reverse-cast metal letters with a 7-degree draft for casting If you're casting pavers, especially those with a pattern, design or wording combination, you'll likely want to have a reusable form with multiple-use letters.Letters made to be reused are generally made of either rubber or metal. Rubber letters are flexible, and so can be compressed to remove from cured (hardened) concrete, and metal letters are made with a 7° draft, which allows them to be removed from the concrete. The draft (slightly sloped sides of the letters) allows the hardened concrete to release the letters, as the fit is a very slight bit wider at the base of the letter as viewed from the side. Regardless of which you use, you will want to oil the letters once you're ready to pour concrete. The rubber and metal letters are made in reverse like a rubber stamp so that the resulting imprint in the concrete reads correctly. See below for using single-use foam letters.                              GET A COST ESTIMATEWhat is the difference in how the letters work?As far as the concrete is concerned, there's little discernible difference to the naked eye. The rubber letters are generally 1/8" to 1/4" [3.18mm to 6.35mm] deep, and so the resulting impression is not very deep. This is best for flat pavers, as water and dirt will not make a deep 'pool' on the surface. For a deeper casting, the metal letters we make are an average 3/4" to 1.5" [19mm-38mm] deep, depending on the letter height. These may be better for vertical concrete casting and deeper cast letter effects. Foam (single-use) letters can be 1/2" to 1-2" thick. Large-cell beaded foam is the most economical but leaves a texture. What if I only need one imprint cast?For a single casting (one side of one sign) it's not very cost-effective to buy letters made to be reused. You can use our very economical large beaded foam letters if the resulting letter "texture" is not a problem, or our smoother smooth-cell foam and gator foam materials. Letters in foam materials are removed or dissolved when removing from hardened concrete, and so are single use.So if you were planning on a mixed-media sign like the one above, we would help you by determining what you need to cast it in concrete (the letters spelling "Sunflower" are embedded in concrete and the panel beneath is made of dimensional letters mounted to a panel shape, which in turn is mounted to the sign face) and to assemble your sign.We have all the D.I.Y. products you need, made to order.   For pricing on the foam letters, send your project details here. Be sure to include your own contact information, along with: Form for a hollow-center columnar cast. Exact wording with the Size of letters (measured by letter height), The desired thickness of letters, Kind of material (foam, metal, rubber) Typestyle if any, otherwise a bold block like the letter "E" above will be used,  and any size or space limitations if there are limits, like a 120-foot width and 40" overall sign height. For example, if your casting area is 24 by 60 inches and you have to make the letters fit, tell us the maximum width and height that the letters must fit within. We can walk you through this- After the first time, it's all common sense. Did I miss something? Leave a comment below.   Fill in the cost estimate form to tell us what you want us to price for you, or send this to a friend who will be considering this project.  We're here to help.   Questions or comments are welcome.                                              GET A COST ESTIMATE Article author Joe Giral is the founder and creative director of LetterBank and My DIY Signs. Your comments are welcome. 

Basic how-to DIY information for using letters to cast concrete forms and pavers.