Relevant Products

EPS Theming Hardcoats

The labor and materials required for large-scale custom design work in the theming and entertainment industry can be time-consuming and costly. Using expanded or extruded polystyrene (EPS or XPS) foam to create new structures has become the preferred method. The process uses a hot wire foam cutter or a 3D foam cutting CNC machine to make intricate pieces quickly. It eliminates errors and allows customers to be 100% confident in precise replication.

Though this process is more accurate and time efficient, EPS does not have the inherent strength to resist impacts or outdoor conditions. Using a hardcoat is the best solution to overcome the limitations of EPS. It provides a fabricated structure with needed strength and durability. Hardcoats are also spray applied to quickly create a desired smooth or textured finish on the foam.

VFI has been producing two-component EPS hard coatings for over 25 years. By offering three types of hardcoats, we can create a spray system that works for your unique project. The type of coating you should use depends on desired application and the durability needed.

Polyurethane hard coats are economical, spray or brush-applied, rigid coatings. They are ideal for use in areas with low traffic or on hanging pieces. They can be easily sanded to provide a smooth, consistent finish.
Polyurea hard coats are more expensive when compared to polyurethane. They have better impact resistance and lower moisture sensitivity during application, making them ideal for high-traffic areas. The outstanding performance of polyurea also allows it to be used in exterior applications.
Polyurea hybrid hard coats combine properties from both polyurethanes and polyureas for an impact-resistant, outdoor-friendly, and sandable coating.

Several of our hardcoat products have fire testing for safe use in both indoor and outdoor environments. Depending on the requirements of the foam structure, we can provide a coating that works for any application. Some applications we’ve seen our products used on include signage, movie and stage props, theme park sets, displays, and much more.