alternative to Gatorfoam

[Tony Rome]

I have been experimenting with cutting (or having Harbor cut) some helmets shapes out for me in gatorfoam for some local schools and then I put decals over them.
However, I realize, this gatorfoam is too expensive. Sure I can fit about 6 on a sheet, but still over $100 for a 4x8, a little salty.
The customer wants that .5" to 1" 3d look. What else could i use that would be less money but that could be cut CLEANLY with a router?

I am not totally opposed to cutting something by hand, but it is so nice when I send it to Harbor and they send it back cut perfect and ready for the decal.

I have tried some cheaper foam, but man the stuff is easy to damage and unforgiving once the decal barely touches it.
With gatorfoam if I make a mistake I can lift it back up.

Any ideas...is gatorfoam just ridiculous and overboard for what I am doing?
It is not like the customer needs it super durable but if it drops I sure would like it to still be OK.

THANKS!!!

 

[phototec]

UltraBoard is a heavy-duty, all-plastic foam board with high-impact litho-grade polystyrene surface and extruded polystyrene core, not resin-impregnated wood fiber surface like Gator Board.

UltraBoard runs about $75-80 a 1/2" x 48' x 96" sheet.

http://www.artsupply.com/foamcore/ultraboard.htm

 

[2B]

try Grimco they have several different brands / prices for foamboard

 

[FS-Keith]

Mdo?

 

[coreyb]

Ultra Board

 

[Tony Rome]

yeah seems like UltraBoard is the only other solution, but sure doesn't save much money. Any advantages other than saving $10

 

[Sign Eagle]

yeah seems like UltraBoard is the only other solution, but sure doesn't save much money. Any advantages other than saving $10

Ultraboard is easier to cut with a knife and the edge of ultraboard is not as sharp, doesn't need to be sanded. Both aterials are available in over size sheets, 5x10, while moe expensive, you might get a better yeald and lower the unit cost.

 

[Typestries]

FWIW, we could supply 1/2" Ultraboard, high quality flatbed print it one sided and rout it for only a bit more than you pay for the routed sheet now. Give me a shout if interested, I won't put prices here but I think you would be surprised. We do a regular run of something very similar for a client in W. Va. on a regular basis and the end users rave about the product. I can send you a printed sample, just shoot me PM or email. Thanks

 

[petepaz]

unfortunately we are always fighting a price/cost issue but some jobs you just can't cut corners. the ultra board or gator are going to give you the best result and if you don't have a router/cnc to cut with you are kind of at the mercy of the vendor.