When someone asks for a rigid sign, we usually ask one question first: where will it live? Indoors on an easel for an afternoon is a very different job from outdoors on a lawn for a month. The answer almost always points to one material or the other.
What each material is
Foam board is a sheet of lightweight foam with a smooth paper or similar facing on each side. It is flat, crisp and very good at showing printed detail. It is made for indoor use.
Coroplast is a brand name that people use for fluted plastic sheet. It has two thin plastic faces joined by ribs, a bit like corrugated cardboard but made of plastic. It is the material behind most yard signs. Ours are 4 mm thick, can be one or two sided and can be paired with H-stands or stakes.
Side by side
| Feature | Foam board | Coroplast |
|---|---|---|
| Weight | Very light | Light |
| Rigidity | Stiff and flat, but it dents and creases | Firm with some flex, springs back well |
| Moisture | Poor, the surface can warp or peel | Handles damp and rain |
| Indoor use | Excellent | Good |
| Outdoor use | Not suitable | Designed for it |
| Print surface | Smooth, great for photos and fine text | Slight ribbing may show on large solid areas |
| Reuse | Gentle handling only | Can be reused many times |
| Edges | Clean but easily damaged | Hardy, edges can be a little ribbed |
Weight and rigidity
If a sign has to sit on an easel or be carried through a hotel lobby, foam board is easier to handle and looks flat and polished. Coroplast has a bit more flex, which is a strength outdoors, since wind can bend it without breaking it. Foam board, on the other hand, can crease when bumped and the damage is difficult to hide.
Moisture and weather
This is the biggest difference. Coroplast is plastic, so rain and snow do not destroy it. Foam board is not made for weather. A damp day can make the surface wrinkle. Direct sun can fade printed colours on either material over time, so plan for the sign's expected lifespan.
Which to pick for common situations
- Open houses: Coroplast for the sign on the lawn. A foam board print inside the home on an easel for the feature sheet or a floor plan.
- Events and weddings: Foam board for welcome signs and seating charts used indoors and then kept as a keepsake.
- Retail: Foam board for window and shelf displays inside. Coroplast for a sandwich-board or curb sign.
- Campaigns and community notices: Coroplast, especially in quantity, since it holds up through weather and can be moved from site to site.
- Trade shows and presentations: Foam board for tabletop displays and mounted posters, and our trade show printing checklist covers what else to bring.
Design tips for either material
Use big, short messages with high contrast. A yard sign is often read from a passing car, so aim for a phone number or web address large enough to read at a glance. For tips specific to lawn signs, see our yard sign printing guide. For foam board images, use sharp photos and check the poster sizes and paper guide for suggested sizes.
If a sign has to withstand weather for a long period or needs to hang from a fence, a vinyl banner may be a better fit. Our banner printing guide can help you compare.
Getting a quote
Tell us where the sign will be used, how long it will be displayed, and how many you need. We will suggest a material and quote it, either on our foam board printing page or for coroplast yard signs. You can also use the quote form. We print for customers in Oakville, Mississauga, Burlington and the wider GTA, and ship across Canada and the USA.
Can I use foam board outside for one day?
It is risky. Dry, calm weather might be fine, but wind and moisture can damage it quickly. If the weather is uncertain, coroplast is the safer choice.
Is coroplast recyclable?
Coroplast is a plastic sheet, and recycling depends on your local program. Check with your municipality, since not all facilities accept it.