Faux Metal Letters Made From “Melted” Styrofoam
I am a little obsessed with “melting” styrofoam lately. It is fun and crazy science and when you mix it with a little creativity you can make some interesting stuff. It does take awhile to harden but once it does you have a lightweight sturdy shape that floats in water.
I am cringing a little as I think of all the times I have thrown away my take out containers and other foam packaging. But now that I know I can make hard plastic from it I will never have to do that again.
It is a simple process to “melt” the foam into a gooey substance using acetone but before you dissolve the foam you need a form to shape it. I have not tried a silicone mold and I don’t know if it would work as the acetone does melt some other plastics. Don’t ask me how I know this. 🙂
I have made the molds for my projects from cardboard boxes partly because I wanted to make my own shapes and partly because I like to re-use the boxes.
To make a cardboard mold start with a template. Trace the template on the a piece of cardboard.
Cut strips of cardboard and use hot glue to attach the sides of the mold. Be sure to keep the glue on the outside of the mold so it does not interfere with the finished shape.
Once the mold is completed it is time to dissolve the foam. Use pure acetone available from home improvement stores to dissolve the foam into a plastic goo.
Place the plastic substance in the mold and allow time to harden. (This shape and thickness took a couple of weeks.)
Once the shape is hardened it is time to remove the cardboard. This is not very easy and does take some scraping, filing, soaking in water and scrubbing.
(To be completely honest after all that I still didn’t get all the remnants of cardboard off but since I decided to paint the letters with a faux metal finish I figured it would be OK.)
For the faux metal finish I used silver spray paint.
To finish the antique look a small amount of black paint was brushed on and then dabbed off with paper towel.
For more details, you can see the whole process here on a smaller project that I made a few weeks ago.
Just in case you didn’t think I was serious about my foam obsession, I made a second letter just for fun.
Happy Upcycling
Dear Cindy,
I was just wondering what sz letter template you used or, where did you get your orginal letter. I’m in cols oh, we have very few craft stores so is there reason I inquire. Thx in advance for any info you can share.
Hi CJ,
Sorry I really don’t remember the size or the font I used to make the cardboard mold. It was something I just printed from my computer. Thanks for checking out my project.
Would it be possible to spray an oil base on the mold befor pouring the styrofoam? Something like a Pam spray? Or even line the mold with cellophane? Just wondering before I give this a try.
Hi CJ I have not tried using cooking spray it might work. I don’t think cellophane is a good idea as acetone dissolves most plastics.
Thanks for your question.
Cindy
Hey, I have been trying to make some Styrofoam letters for my sister’s baby shower,Can you provide me with some help on which letters to choose and what colors to add.Any help will be highly appreciated.
Do you think covering the card board, BEFORE gluing the mold together, w/ a non-stick tin-foil would help it not stick so bad? Walmart & Food Lion now have their own version of it and they are a $1 or 2 cheaper than Reynolds. 😉
That could work but I have not tried it. Thanks for your comment.
That’s an amazing task you did with the styrofoam. I want to know the durability of the faux metal letter. Wether if it starts breaking by itself on exposure to sun or rain, etc.
Thanks for your comment. Sorry I can’t really answer your questions as I have not exposed the this to sun although I don’t think that water would be a problem.
This is an AMAZING idea!
If an oil spray or Vaseline, etc., makes the mold easy-release, why not make your cardboard mold backward so when you remove the hardened foam, your letter would have a flat smooth front? This might eliminate the need to do so much smoothing/sanding.
Just my two-cents.
Thanks Laura,
I appreciate your ideas. I may have to give it a try.
I hope you do! And if so, please post it, I’d love to see how it turns out. Your ideas are SO clever! Wish I had a brain like yours.
Do you think liquid fabric softener would help removing the cardboard? It works great on removing wall paper
Sorry I don’t know I have not used liquid fabric softener before but when it comes to crafting I will pretty much try anything. 🙂
That is about the coolest thing I’ve ever seen. Do you know if it were pressed between two different sized bowls if the bowls could be separated? Or if it would stand up to the elements if it were used for planters outdoors in the garden?
I like your idea. I am not sure if it would work or not. The project needs air to harden and until the foam goo is dry it is kind of sticky.
But you could always give it a try.
If I were using two different sized bowls/forms I would try either spraying with cooking oil (Pam, etc.) or wiping a small layer of vaseline on the surfaces the foam would touch. That should allow for a quick release. Vaseline would probably work for the paper, too.
I really love this project. I never thought there was anything I could make with styrofoam. I will try either the spray oil or Vaseline in the mold and make my project outside. Thanks for sharing.
Like this project MUCHLY! Thank you for sharing it.
Regarding the sticking problem…would spraying the mould with oil spray not help in releasing the end product?
Hi Dee,
I have not tried cooking spray. It might work.
This styrofoam project is absolutely brilliant. I’m in awe. Thank you.
Cindylou
Great idea! Have you tried putting a coat of Vaseline on your form to help removal of the cardboard?
I have not tried to use any type coating on the cardboard. If you do let me know how it works. 🙂
Thank you for sharing Cindy,
This is the best thing I have seen for up cycle in a long time. I see myself making allot of different things with hard to deal with foam.
I have never liked it going to the dump.
How are the fumes? I know pure acetone can be strong but I am not sure about the chemical fumes created by the dissolving of the plastic?? Does this need to be done in a well ventilated area?
A well ventilated area is always a good idea. There are some other tips on the “dissolving” process in this video.
a BRILLIANT idea! but I too wonder about any fumes that will, I’m sure be created during the melting of the styrofoam.
Even if we can’t smell it, it doesn’t mean it isn’t harmful.
Sorry, don’t mean to be a wet blanket on what is a terrific idea, just want to be safe! Thanks for one great idea DN