A couple (maybe dumb) questions about foam dimensional letters

I haven't been on here much lately. Business took a bit of a hit between the economy and the fire we had a few months back. Things are finally getting back to normal, and I wanted to start back into the signs101 community by posing a couple questions that have been bugging me for awhile.

I've done quite a few interior dimensional letting jobs over the past couple years, but my processes are a bit too tedious and I'm looking to take things up a notch.

I have been using our AXYZ CNC router to cut letters/logos out of gator foam. Then I airbrush Delta Ceramcoat All Purpose Sealer to seal/prime the edges & faces before finally airbrushing the finish paint color. It works, but it takes FOREVER.

While this does yield good results, they could be better. This is especially noticeable when I look at similar products from, say, Howmac.

Thus the questions are;

-What sort of machine does someone like Howmac to cut things like this? Their edges are always perfect and the inner corner radii are so tight that I'm led to believe it's something other than a CNC router. It is some kind of wire cutter?

-What methods of painting gator foam have any other Signs101 members employed? There must be quicker/better materials or processes than what I'm doing now.

Thanks!

 

Howmac is a wholesale supplier.

http://www.howmac.com/

They do fantastic work and I still use them when I need to, but I try to do as many things in house as I can.

 

I try (and prefer) to use PVC where I can. It's more durable for the customer and more forgiving for me in production. However, I do have customers who simply INSIST on a soft foam core type product.