Bringing “Protect the Fun” to Life

When Banana Boat approached us with the vision of a memorable, interactive event installation, we knew our expertise in large-format replicas and high-density materials would help create something extraordinary. The result is an engaging, 72-inch-tall sunscreen packet holder shaped like Banana Boat’s signature Sport spray bottle—complete with a midsection shelf featuring slits on each side to dispense packets of sunscreen. Crafted from high-density CNC-cut foam and finished with vibrant paints, this lightweight yet sturdy installation stood proudly outdoors, inviting fans to “Protect the Fun” while offering convenient access to product samples.

Concept and Collaboration

Our collaboration with Banana Boat began with a kickoff meeting to explore the goals for their outdoor event display. They wanted more than a static prop—they needed a functional replica that could hold and distribute sunscreen packets in high traffic settings. We discussed desired dimensions, graphic elements, and how the shelf mechanism would integrate seamlessly into the bottle form. From initial sketches to 3D renderings, our design team worked closely with Banana Boat’s marketing group to ensure brand consistency: the proportions had to match the real Sport bottle, and the color palette needed to reflect Banana Boat’s vibrant yellow, deep blue, and bold orange accent.

Material Selection: High-Density Foam

To achieve the balance between visual impact and ease of handling, we specified high-density polyurethane foam as the core building material. This foam offers exceptional rigidity and surface smoothness, ideal for capturing precise contours via CNC machining. At approximately 2.5 pounds per cubic foot, the foam is light enough for a small crew to install and dismantle, yet dense enough to withstand multiple days of outdoor use. Its closed-cell structure resists moisture, allowing the piece to maintain integrity even in dewy morning conditions.

Precision Fabrication with CNC Cutting

Once the digital design was finalized, our engineers translated the 3D model into toolpaths for CNC machining. Each major component—the front and back bottle halves, the side panels, and the internal shelf assembly—was cut to tolerances within 1/16th of an inch. This level of precision ensured that pieces fit together flush, without gaps, and that the slits in the shelf aligned perfectly to hold individual sunscreen packets upright. We also carved mounting points for hidden dowels and mechanical fasteners that lock the halves together, creating a unified structure with no visible seams.

Assembly and Structural Reinforcement

Despite its foam construction, the replica needed to be rock solid when guests reached for samples. To reinforce the foam shell, we integrated lightweight aluminum brackets and internal cross-members in strategic locations behind the foam panels. These supports tie into the bottom base plate, a custom-cut HDPE sheet that distributes load evenly. The shelf itself features channel supports beneath the foam surface, preventing sagging when fully stocked with sunscreen packets. Our assembly technicians used high-strength epoxy adhesives and stainless-steel fasteners to join components, ensuring the installation could stand up to enthusiastic engagement.

Surface Preparation and Protective Coating

A smooth, paint-ready surface is critical for achieving the bold, glossy finish Banana Boat required. After assembly, the foam shell received multiple skim-coats of automotive-grade polyurethane primer. Each coat was sanded progressively from 220 grit to 400 grit, resulting in a near-glassy substrate. We then applied a clear coat of polyurea-infused primer sealer to seal the foam pores and protect against abrasion. This step also ensures adhesion of the topcoat and guards the installation against scuffs and UV exposure during outdoor use.

Vibrant Brand Colors and Detailing

With the surface fully prepared, our paint specialists brought the design to life using premium, UV-resistant acrylic enamels. The main body received layers of Banana Boat yellow, accented by deep blue panels and bright orange trigger details. Masking lines were laid out by hand to replicate the exact curves and proportions of the original Sport bottle graphics. A final gloss clear coat adds depth and sheen, making the foam replica appear indistinguishable from an actual product canister at a glance.

Shelf Integration and Packet Dispensing

The heart of the installation is the built-in shelf mechanism. Positioned approximately 36 inches above the base, the shelf spans the internal width of the bottle form and features precision-cut slits on both sides. Each slit holds a row of Banana Boat sunscreen packets in upright fashion, allowing passersby to easily grab a packet without touching neighboring items. To ensure smooth dispensing, we rounded the edges of the slits and applied a silicone sealant to reduce friction. The shelf is set at a slight rear tilt—just 5 degrees—to use gravity to gently fan out the packets for a more dynamic presentation.

Weatherproofing for Outdoor Durability

Because the installation was destined for an open-air event, we took extra measures to weatherproof every component. All metal reinforcements were treated with zinc-rich primer and powder-coated black. The bottom base plate features discreet drainage channels to prevent water pooling. Sealants were applied around seams to repel rain and humidity. Even the epoxy adhesives we selected boast marine-grade durability. Our testing simulating overnight dew and direct sunlight confirmed that colors remain vibrant and structural components remain stable, even after multiple exposure cycles.

Safe, Efficient Installation

Transporting a 72-inch foam replica to the event site posed a logistical challenge we were well-prepared to meet. The installation was shipped in two nested crates: one containing the assembled base and internal brackets, the other holding the body shell and shelf unit. At the venue, our crew used light-duty dollies and soft straps to maneuver the components into position. Assembly required only standard tools—an electric drill, torque wrench, and caulk gun. In under two hours, the piece stood fully erected, anchored by discreet ground stakes that prevent tipping in breezy conditions.

Engaging Attendees and Amplifying Brand Presence

From the moment doors opened, guests gravitated toward the larger-than-life Sport bottle. Visitors paused to take selfies beside the installation, and the convenient shelf encouraged sampling—packets flew off the slits faster than anticipated, a testament to the design’s effectiveness. Brand ambassadors staffed the booth, using the replica as a focal point for product demonstrations. Social media posts tagged #ProtectTheFun and #BananaBoat soared as attendees shared their photos and experiences. By integrating form and function, the installation became both an eye-catching sculpture and a practical giveaway station.

Post-Event Evaluation and Reuse Potential

Following the event, Banana Boat’s marketing team provided glowing feedback: the installation not only drew crowds but also facilitated streamlined distribution of their new packet format. We conducted a thorough debrief, inspecting each component for wear. The foam shell remained impervious to dings, and the paint finish showed no signs of chipping. The aluminum reinforcements and shelf bracket performed flawlessly. Based on these results, Banana Boat has expressed interest in repurposing the installation for future outdoor events, trade shows, and regional activations. Our modular design allows for quick disassembly, on-site touch-up, and reassembly, extending the value of the investment.

Sustainability Considerations

In selecting materials and processes, we also considered environmental impact. High-density foam can be recycled at specialized facilities, and all paints and primers meet low-VOC standards. The aluminum reinforcements are made from 100% post-industrial recycled content. After its lifecycle as an event prop, the piece can be transformed into an in-store display or educational exhibit at community centers. By designing for durability and adaptability, we help clients maximize utility while minimizing waste.

A Showcase of Craftsmanship and Creativity

This Banana Boat Sport bottle replica represents the intersection of artistry, engineering, and brand storytelling. From the first sketches to the final clear coat, our team applied meticulous attention to detail. The high-density foam provided the perfect canvas for CNC precision, while structural reinforcements ensured stability. The shelf mechanism exemplifies our ability to integrate interactive features without compromising aesthetics. In every phase—design, fabrication, finishing, and installation—we remained focused on delivering an installation that not only looks spectacular but also functions seamlessly in a real-world, high-traffic environment.

Conclusion: Protecting the Fun, One Packet at a Time

Through collaborative visioning, expert material selection, and precision fabrication, we delivered a 72-inch-tall Banana Boat Sport bottle replica that captivates audiences and effectively distributes sunscreen packets. This installation exemplifies how thoughtful design transforms brand messaging into immersive experiences. As attendees slather on their sunscreen and share photos across social channels, Banana Boat’s message to “Protect the Fun” resonates loud and clear—thanks in no small part to an installation that combines form, function, and flair in equal measure.