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Rigid Sign Materials, Compared
Updated August 2026
5 materialscoroplast, foam, Sintra, styrene, Alupanel
Indoor + outdoora right answer for each
60 inmax single-piece print width
2-7 daysproduction, rush available
Choosing a sign material is a durability-for-dollars decision, and the wrong choice wastes money in both directions: foam board dies in one rainfall, and Alupanel is overkill for a weekend event. Here is how the five materials we print actually compare, so you buy the cheapest material that survives your job.
The comparison
| Material | Build | Where it lives | Lifespan logic |
|---|---|---|---|
| Coroplast | Corrugated plastic, 4 mm | Outdoors, temporary | A season of weather: lawns, events, campaigns |
| Foam board | Foam core, paper faces | Indoors only | Displays, presentations, photo props; fragile, but light and cheap |
| Styrene | Thin solid plastic | Indoors | More flex and durability than foam board; retail and POP signage |
| Sintra PVC | Solid PVC sheet | Indoors or outdoors, permanent | Durable outdoor signage without metal pricing |
| Alupanel | Aluminum composite panel | Outdoors, permanent | The premium option: rigid, flat, built for years of service |
The decision in three questions
1. Inside or outside? Indoors, foam board and styrene cover almost everything. Outdoors, they are eliminated immediately: foam board in particular does not survive weather.
2. How long does it need to last? Outdoors for a season: coroplast, and stop spending there. Outdoors for years: Sintra PVC, or Alupanel when flatness and premium finish matter, like storefront and building signage.
3. Does it travel or get handled? Styrene tolerates handling better than foam board. Anything wall-mounted permanent wants Sintra or Alupanel.
Sizes
We print up to 60 inches wide on a single piece across these materials. Larger graphics are produced by tiling panels.
File setup
- CMYK color at 300 DPI
- 0.125 in bleed on all trimmed edges
- Fonts converted to outlines
- PDF, JPEG, TIFF or EPS
Unsure whether your artwork holds up at sign size? Our in-house design services can check and rebuild it for large format.
Turnaround and shipping
Most small jobs run 2 to 7 business days depending on the production speed selected, with rush available. We ship throughout Canada and the United States, and ground shipping is free on orders over $200.
Frequently asked questions
What is the difference between coroplast, foam board and Sintra PVC? Coroplast is lightweight corrugated plastic for temporary outdoor signs. Foam board is for indoor use and is more fragile. Sintra PVC is durable and suited to permanent outdoor signage.
Which sign material is best for outdoor use? For temporary outdoor use, coroplast. For permanent outdoor signage, Sintra PVC or Alupanel, which is an aluminum composite panel built for long service outdoors.
Which sign material is best for indoor displays? Foam board is the classic indoor display material: light, flat and economical. Styrene suits indoor signage that needs more flex and durability than foam board.
What is Alupanel? Alupanel is an aluminum composite panel: two thin aluminum faces bonded to a core. It is rigid, flat and durable, which makes it the premium choice for permanent outdoor signs.
How large can you print a rigid sign? We print up to 60 inches wide on a single piece. Larger graphics are produced by tiling panels.
How fast can you print rigid signs? Most small jobs run 2 to 7 business days depending on the speed selected, and rush service is available.
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